Systems and methods for high speed array printing and hybridization

ABSTRACT

Novel and improved systems and methods for high speed arraying, hybridization, quantitative development and/or assaying are provided. Some embodiments provide a web based arraying format. Some other embodiments provide a sheet based arraying format. Some embodiments use a drop on drop assaying or hybridization mode. In some embodiments, a substantially inert substrate is utilized. In some other embodiments, an interactive substrate is utilized.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates in general to diagnostic systems and methods and,more particularly, to systems and methods for high speed array printing,hybridization, quantitative development and assaying.

2. Description of the Related Art

Diagnostic formats involving microarrays or biochips continue to have abroad range of applications, such as, but not limited to, the fields ofgenomics and proteomics, among others. These technologies not onlyrelate to the creation of the arrays but also to their processing andassaying such as hybridization. In many cases, valuable reagents need tobe effectively utilized in small quantities which can be as low in thepicoliter range.

Conventional systems, technologies and processes used in and/orassociated with such diagnostic applications suffer from many drawbacks.These can include procedures which are relatively slow, takeconsiderable time and hence are unable to achieve a desirably highthroughput—this not only reduces process efficiency but also undesirablyadds to the cost. Moreover, it is a difficult task to effectivelyutilize small quantities of chemical or biological reagents and otherliquids when complex steps to precisely handle, transfer, deliver andprocess such small liquid quantities are entailed.

SUMMARY OF THE INVENTION

Microarrays or biochips are beginning to evolve into useful diagnosticformats for a broad range of applications that include, but are notlimited to, human, veterinary, agriculture, and food markets, amongothers. The arrays can be based on a wide range of sensor molecules thatinclude, but are not limited to, DNA, Oligonucleotides, proteins,antibodies, carbohydrates, cells, and small molecules, among others.

Research arrays tend to have high densities in the range of five to tensof thousands of spots or greater in order to achieve maximuminformation. Diagnostic applications are highly focused on a smallnumber of targets and hence tend to have densities in the hundreds ofspots or less.

Traditionally microarray development has been based on the use of smallspots on a substrate such as glass where the spot sizes are typically inthe range of about 100 microns (μm) to about 300 microns (μm). This hasallowed spot densities in excess of 50,000 to be printed on a glassslide.

Spotting has been done with contact pins and piezoelectric non contactdispensing of drops in the picoliter range. Another driving force forusing small spots has been the cost of the reagents for large spottinglibraries. Research and development (R&D) arrays are typically printedin volumes under 200,000 per year as the conventional processingthroughput is disadvantageously slow due to both the process speed andnumber of spots being printed.

Traditional microarraying is based on the use of aspiration and dispenseprocesses where the source chemistries are presented in microtiter plateformats from which the reagents are aspirated and then dispensed (A/D)onto the array substrate. This conventional process undesirably requiresa careful cleaning process each time the reagents are changed whichresults in a high overhead time and thus disadvantageously reducesproduction throughput.

This is the case for both conventional non-contact and contactdispensing approaches. These approaches can also undesirably wastevaluable reagents due to washing, drying and/or dilution of the targetreagents during the spotting process. Hence, high throughputmanufacturing requires the use of bulk reagent dispensing usingindependent dispense heads.

The challenges for the adaptation of microarrays to large marketdiagnostic applications wherein the number of devices will be in therange from about 1 million to about 1,000 million lies in the ability toestablish manufacturing strategies that can achieve array formatdensities and throughput capabilities. Other desirable features willinclude the ability to achieve performance coefficient of variations(CVs) and satisfy validation protocols.

Another important consideration for microarray formats is thehybridization process which develops the manufactured test for reading.Current methods of hybridization are undesirably slow and not suitablefor major market segments such as point of sample testing (PST) whereinit is desirable to achieve test and read times typically less than 10minutes. Disadvantageously, current hybridization techniques requiremuch longer times while using expensive equipment with low throughputcapabilities.

Advantageously, and as described further herein, systems and methods forhigh speed (and/or throughput) array printing, hybridization,quantitative development and assaying in accordance with certainembodiments of the invention achieve some or all of the above-mentioneddesired or needed goals and/or objectives, and solve some or all of theabove-mentioned problems and/or drawbacks.

Certain embodiments provide novel and improved systems and methods forhigh speed arraying, hybridization, quantitative development and/orassaying are provided. Some embodiments provide a web based arrayingformat. Some other embodiments provide a sheet based arraying format.Some embodiments use a drop on drop assaying or hybridization mode. Insome embodiments, a substantially inert substrate is utilized. In someother embodiments, an interactive substrate is utilized.

In accordance with some embodiments a high speed array manufacturingsystem is provided. The system generally comprises a dispense module anda controller. The dispense module comprises a plurality of non-contactdispensers arranged in a predetermined configuration with apredetermined spacing for dispensing reagent drops onto a substratemedium. The controller provides relative motion between the dispensersand the substrate medium on which an array is formed to manufacture asubstrate structure for assaying. The array has reagent spots dispensedon the substrate medium with spacings that are less than the spacingsbetween the dispensers to form a high density substrate structure.

In accordance with some embodiments a high speed assaying system isprovided. The system generally comprises a dispense module and acontroller. The dispense module comprises a dispense head and a motionpositioner. The dispense head comprises a plurality of non-contactdispensers arranged in a predetermined configuration with apredetermined spacing for dispensing reagent drops onto an arraysubstrate with target spots formed thereon or therein such that thedrops are precisely delivered at the position of the selected targetspots. The controller monitors and controls said dispensers and therelative motion between the dispensers and the array substrate.

Some embodiments provide a combined high speed array manufacturingsystem and high speed assaying system. In some embodiments, the assayinginvolves hybridization. In some embodiments, the assaying involves PCRassaying.

For purposes of summarizing the invention, certain aspects, advantagesand novel features of the invention have been described herein above. Ofcourse, it is to be understood that not necessarily all such advantagesmay be achieved in accordance with any particular embodiment of theinvention. Thus, the invention may be embodied or carried out in amanner that achieves or optimizes one advantage or group of advantagesas taught or suggested herein without necessarily achieving otheradvantages as may be taught or suggested herein.

All of these embodiments are intended to be within the scope of theinvention herein disclosed. These and other embodiments of the inventionwill become readily apparent to those skilled in the art from thefollowing detailed description of the preferred embodiments havingreference to the attached figures, the invention not being limited toany particular preferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus summarized the general nature of the invention and some ofits features and advantages, certain preferred embodiments andmodifications thereof will become apparent to those skilled in the artfrom the detailed description herein having reference to the figuresthat follow, of which:

FIG. 1A is a simplified view of a Scienion sciFLEXARRAYER™ S3 piezodispenser illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 1B is a simplified view of a Scienion sciFLEXARRAYER™ S5 or S11piezo dispenser, and an enlarged view of a dispensing head thereof,illustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 1C is a simplified view of a piezo dispenser illustrating featuresand advantages in accordance with certain embodiments of the invention.

FIG. 2A is simplified schematic view of a BioJet Quanti™ dispenserillustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 2B is simplified schematic view of a BioJet Plus™ dispenserillustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 2C is a simplified view of a dispensing apparatus illustratingfeatures and advantages in accordance with certain embodiments of theinvention.

FIG. 2D is a simplified view of a dispensing apparatus with multipledispensers and illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 2E is a schematic generalized illustration of a dispensingapparatus with an array of dispensers and illustrating features andadvantages in accordance with certain embodiments of the invention.

FIG. 2F is a simplified view of a dispensing apparatus with a manifoldand illustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 2G is a cross-sectional view of a solenoid valve dispensing headfor use in accordance with any of the embodiments of FIGS. 2A-2F.

FIG. 2H is a cross-sectional view of a piezo electric dispensing headfor use in accordance with any of the embodiments of FIGS. 2A-2F.

FIG. 2I is a cross-sectional view of a dispensing tip for use inaccordance with any of the embodiments of FIGS. 2A-2H.

FIG. 2J is a top view of the tip of FIG. 2I.

FIG. 2K is a top view of the tip of FIG. 2I.

FIG. 2L is a cross-sectional view of a positive-displacement syringepump for use in accordance with either of the embodiments of FIGS.2A-2F.

FIG. 2M is a graph illustrating initial (non-steady-state) dispensevolumes versus target dispense volumes for a reagent dispensing methodand apparatus in accordance with one embodiment of the invention andshowing the effects of reagent pre-pressurization.

FIG. 3 is a simplified top view of a 16-spot array or microarraysubstrate illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 4 is a simplified top view of a 40-spot array or microarraysubstrate illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 5 is a simplified top view of a 3,000-spot array or microarraysubstrate illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 6 is a simplified perspective view of an array or microarray basedweb design substrate or substrate assembly illustrating features andadvantages in accordance with certain embodiments of the invention.

FIG. 7 is a simplified top view of the web design substrate or substrateassembly of FIG. 6 illustrating features and advantages in accordancewith certain embodiments of the invention.

FIG. 8 is a simplified enlarged view along line 8-8 of FIG. 7.

FIG. 9 is a simplified side view of a web based array assembly systemillustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 10 is a simplified end view of the web based array assembly systemof FIG. 9 illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 11 is a simplified top view of the web based array assembly systemof FIG. 9.

FIG. 12 is a simplified enlarged view along line 12-12 of FIG. 11illustrating features and advantages in accordance with certainembodiments of the invention.

FIGS. 13A and 13B are simplified views of an aspirating and dispensingsystem illustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 14 is a simplified view of an aspirating and dispensing systemillustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 15 is a simplified perspective view of a sheet based array assemblymodule or system illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 16 is a simplified perspective view of an inert substrate assemblyor structure illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 17 is a simplified perspective view of an interactive substrateassembly or structure illustrating features and advantages in accordancewith certain embodiments of the invention.

FIG. 18 is a simplified perspective view of a PCR conducive substrateassembly or structure illustrating features and advantages in accordancewith certain embodiments of the invention.

FIG. 19 is a simplified schematic view of precision drop on drop (orspot) dispensing for assaying purposes illustrating features andadvantages in accordance with certain embodiments of the invention.

FIGS. 20-23 are various simplified views of a bench top hybridization(and/or assaying) system illustrating features and advantages inaccordance with certain embodiments of the invention.

FIG. 24 is a simplified perspective view of a sample storage, dispensemaster mix and magazine loader system illustrating features andadvantages in accordance with certain embodiments of the invention.

FIG. 25 is a simplified perspective view of a hybridization and readingsystem illustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 26 is a simplified enlarged view along line 26-26 of FIG. 25illustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 27 is a simplified side view of an arraying, hybridization andreading system illustrating features and advantages in accordance withcertain embodiments of the invention.

FIG. 28 is a simplified top view of the arraying, hybridization andreading system of FIG. 27 system illustrating features and advantages inaccordance with certain embodiments of the invention.

FIG. 29 is a simplified end view of the arraying, hybridization andreading system of FIG. 27 system illustrating features and advantages inaccordance with certain embodiments of the invention.

FIG. 30 is a simplified perspective view of the arraying, hybridizationand reading system of FIG. 27 system illustrating features andadvantages in accordance with certain embodiments of the invention.

FIG. 31 is a simplified enlarged view along line 30-30 of FIG. 30illustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 32 is a simplified side view of a web based interactive arrayassembly system with a blocking module illustrating features andadvantages in accordance with certain embodiments of the invention.

FIG. 33 is a simplified top view of the web based interactive arrayassembly system of FIG. 32 illustrating features and advantages inaccordance with certain embodiments of the invention.

FIG. 34 is a simplified end view of the web based interactive arrayassembly system of FIG. 32 illustrating features and advantages inaccordance with certain embodiments of the invention.

FIG. 35A shows simple views of various species whose genes can beprovided for assaying illustrating features and advantages in accordancewith certain embodiments of the invention.

FIG. 35B is a simplified view of TaqMan® PCR assaying mechanismillustrating features and advantages in accordance with certainembodiments of the invention.

FIG. 35C is a simplified schematic view of a gene expression analysisworkflow or flowchart illustrating features and advantages in accordancewith certain embodiments of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the invention described herein relategenerally to diagnostic systems and methods and, in particular, tosystems and methods for high speed array printing, hybridization,quantitative development and assaying.

While the description sets forth various embodiment specific details, itwill be appreciated that the description is illustrative only and shouldnot be construed in any way as limiting the invention. Furthermore,various applications of the invention, and modifications thereto, whichmay occur to those who are skilled in the art, are also encompassed bythe general concepts described herein.

Some Non-Contact Dispensing Technology Embodiments

The working drop volume range suitable for production arrays lies in therange of picoliters to nanoliters which, in certain embodiments, isdelivered by non contact methods in order to desirably meet processspeeds which are suitable for high production throughputs.

In some embodiments, to dispense drops in the picoliter volume range, astate of the art technology and product base as available from ScienionAG of Berlin, Germany is utilized to deliver reagent at rates of up toabout 5 drops/second using step and repeat indexing methods using bulkdispensing. In certain embodiments, an on the fly dispensing mode isutilized to increase this throughput to about 20 to about 50 depositionsper second per dispenser, including all values and sub-rangestherebetween. In some embodiments, such as on the fly dispensing, thethroughput is in the range from about 20 to about 500 depositions persecond per dispenser, including all values and sub-ranges therebetween.

Scienion has also developed a disposable or reusable tip integrated witha piezo actuator for bulk dispensing of reagents known as SciSwift. Thistip, in some embodiments, can be integrated into various machineconfigurations suitable to meet high throughput production requirements.

FIGS. 1A and 1B show various views and illustrate various features ofScienion sciFLEXARRAYER™dispensing (and aspirating) and liquid handlingsystems (400, 400′) used in conjunction with systems and methods inaccordance with certain embodiments of the invention. U.S. Pat. No.6,599,479 B1, the entirety of which is hereby incorporated by referenceherein, discloses a piezo electrically triggered multi-channeldispensing (and aspirating) system (one embodiment is shown in FIG. 1Cand referred to by reference numeral 410) which can be efficaciouslyutilized in accordance with certain embodiments of the invention. It isto be understood, that this patent document comprises a part of thepresent patent specification/application.

In general, the sciFLEXARRAYER embodiments provide ultra-low volumedispensing systems for R&D and manufacturing. The sciFLEXARRAYER productlines represent desirable tools for automated ultra-low volume liquidhandling of biological samples in diagnostics, genomics and proteomics,among others.

In brief, certain embodiments of the sciFLEXARRAYER piezo dispensers arenon-contact systems for producing high-quality, DNA micro-arrays,porotein micro-arrays, reversed phase protein micro-arrays, celltransfection arrays, and Glycan micro-arrays. Also, in brief, certainembodiments of the sciFLEXARRAYER piezo dispensers are non-contactsystems for loading of biosensors, and matrix-assisted laserdesorption/ionization (MALDI) targets. These embodiments are, withoutlimitation, also operable in conjunction with many other ultra-lowvolume applications.

Advantageously, the sciFLEXARRAYER embodiments are capable ofintegration with well established technologies and also address theneeds of specific customer needs from early research to high throughputmanufacturing.

With particular reference to FIG. 1A, the dispensing system or apparatus400 is a non-contact piezo dispenser for automated ultra-low volumeliquid handling. This system 400 is desirably engineered robustly tohandle many delicate substrates, advantageously provides a flexible toolin R&D and/or as reliable workhorse for manufacturing high qualityarrays. Certain embodiments of the system 400 are specifically designedas beneficially providing a versatile tool in R&D. The dispensing system400 of some embodiments provides an unsurpassed piezo-dispensingtechnology affordable, for example, for academic budgets. High-qualityarrays can be desirably loaded, for example, MALDI targets orbiosensors, among others, with efficacy.

Continuing with a discussion of the product description of thedispensing and arraying system 400, this technology involves anautomated piezo driven non-contact dispensing system of ultra-lowvolumes, which in some embodiments, is specifically designed aseconomical entry unit for academic and R&D labs. Certain embodiments ofthe system 400 comprise an XYZ-stage with spindle drive, a piezodispensing unit and a precision equipment for liquid handling. Thesystem 400, in some embodiments, handles volumes from 100 picoliters upto several microliters. Advantageously, the system 400 is suitable forthe production of DNA and protein microarrays, for cell transfectionarrays, and for loading Matrix assisted Laser Desorption Ionisation MassSpectrometry (MALDI-MS) targets or biosensor surfaces, among otherfeatures.

Embodiments of the system 400 desirably provide a heavy duty design andlow maintenance components for long-term use as a flexible and highlydependable tool for drop-on-demand dispensing.

The system 400 advantageously provides several beneficial features andis particularly designed for a number of applications. These include,without limitation: DNA, protein, glycan arraying and biosensor loading;cell transfection arrays (and arraying); MALDI-MS sample preparation andtarget loading; accurate dilution series or addition of tiny aliquots ofand/or to samples; printing chemical libraries; spotting onto customizedtargets, e.g. disc format (round targets or radial designs); assaydevelopment; and microarray-based analysis.

Some technical information relating to certain embodiments of thedispensing system 400 is presented in TABLE 1 below:

TABLE 1 Dispensing System 400 Piezo Dispensing Non-contact,drop-on-demand No. of dispense 1-8 (in any combination) capillariesMinimum distance of 4.5 mm dispense capillaries Dispense volume 100-500picoliter (pL) per droplet Capillary orifice 50-90 microns (μm)Capillary material Borosilicate glass Typical spot size 120-250 μmTypical pitch (spacing) 300 μm (scaleable) Dispense control Integratedhorizontal CCD Software: Windows XP based Capacity 1 holder (sourceplate) à 170 × 90 mm (MTP); 2 holders (targets) for a total of 20standard glass slides; or 2 holders (target plates) à 170 × 90 mm (MTP)Dimensions with 83 × 85 × 65 centimeter (cm) enclosure (D, W, H) Weight120 kilograms (kg)

Several options are also available in conjunction with the dispensingsystem 400 for specific applications. These include, without limitation:humidity control; cooling unit; clean room; head-mounted camera; andsoftware option for camera-based applications.

A wide variety of software systems may be used to control and coordinatethe operation of the dispensing system 400. Advantageously, someembodiments of the software provide, without limitation: flexible andeasy design of chip layout without any or minimal restrictions;programming of individual spotting routines by the user(s); a userfriendly interface; and set-up of individual user profiles.

Embodiments of the dispensing system 400 desirably provide forindividual configurations and enhanced versatility. For example, andwithout limitation: customization of hardware and software (e.g.environmental controls, software for pattern recognition); camera-basedspotting (e.g. calculation of spot positions with guide dots); andbarcodes (e.g. for identification and tracking).

With particular reference to FIG. 1B, the dispensing system or apparatus400′ is a non-contact piezo dispenser for automated ultra-low volumeliquid handling. This figure also shows an enlarged view of a dispensehead 401 of the system 400′ comprising a plurality of dispensingchannels or capillaries 402.

The dispensing system 400′ provides a number of benefits and advantages.These include, without limitation: non-contact liquid handling ofvolumes from picoliter to microliter; the system's precise, robust X-Ymagnetic linear stage is fast and maintenance-free; the transferredvolume is constant and not affected by the target; non-contactdispensing substantially eliminates or reduces risk of contamination;“free-fly” of droplets allows dispensing into small cavities;re-spotting is facilitated by the system's drop-on-demand feature;efficient mixing of reagents is achieved; the dispense head 401 orindividual capillaries 402 are easily changeable; exchange of targetholders is swift and convenient; and the auto-drop function provides fora walk-away system.

Advantageously, the system 400′ can be efficaciously utilized in a widevariety of applications. These include, without limitation: DNA,protein, glycan, and cell transfection arrays (and arraying); loading ofbiosensors; MALDI-MS sample preparation and target loading; accuratedilution series or addition of tiny aliquots to (and/or of) sample;printing chemical libraries; spotting onto disc format (round targets)and customized targets; assay improvement and screening assays; and anymicroarray-based analysis.

Some technical information relating to certain embodiments of thedispensing system 400′ is presented in TABLE 2 below:

TABLE 2 Dispensing System 400′ Piezo Dispensing Non-contact,drop-on-demand No. of dispense capillaries 1-8 (in any combination)Minimum distance of dispense 4.5 mm capillaries Dispense volume 100-500picoliter (pL) per droplet Capillary orifice 50-90 microns (μm)Capillary material Borosilicate glass Typical spot size 120-250 μmTypical pitch (spacing) 300 μm (scaleable) Dispense control Integratedhorizontal CCD camera system allows: manual or fully automated operationwalk-away system, allows unattended production Software Windows XP basedCapacity- S5 embodiment 5 holders à 170 × 90 mm Capacity- S11 embodiment11 holders à 170 × 90 mm Dimensions (D, W, H) - S5 850 × 580 × 450millimeter (mm) embodiment Dimensions (D, W, H) - S11 1400 × 580 × 450mm embodiment

Several options are also available in conjunction with the dispensingsystem 400′, for example, for specific applications. These include,without limitation: humidity control; cooling unit; clean roomenclosure; head-mounted camera; and software option for camera-basedapplication.

A wide variety of software systems may be used to control and coordinatethe operation of the dispensing system 400′. Advantageously, someembodiments of the software provide, without limitation: a userfriendly, straight forward interface; flexible and convenient design ofchip layout; no restrictions on target patterns, even radial designs;library of spotting routines (easily customizable); and individual userprofiles.

Embodiments of the dispensing system 400′ desirably provide forindividual configurations and enhanced versatility. For example, andwithout limitation: customization of hardware and software (e.g.environmental controls, software for pattern recognition); connection toexternal equipment (e.g. plate hotels); camera-based spotting (e.g.calculation of spot positions with guide dots); and barcodes (e.g. foridentification and tracking).

In some embodiments, a sciFLEXARRAYER S100 dispensing device (“theS100”) available from Scienion AG of Berlin, Germany is utilized forliquid handling operations. The S100 is advantageously a top level highthroughput production device, and provides a high throughput array andbiosensor production instrument. Desirably, the S100 meets the highthroughput production requirements of most bioarray formats likemicrotiter plates (MTPs), slides, wafers and a variety of biosensors,among others.

In embodiments of the S100 sciFLEXARRAYER, the targets are moved towardsthe dispense head mounted on each S100 portal and between each S100portal via a conveyer belt. In some embodiments, each dispense head canbe equipped with up to 12 sciSWIFT cartridges or sciDROP dispensers.Advantageously, this modularity allows the exact configuration of thesystem to the production volumes required. Moreover, and desirably, forcustomer specific applications, the system can be modified to meet anyrequest (or a wide range of requests) for a variety of carrier formats.Additionally, the system can readily be adapted for specialrequirements, e.g., for software and hardware customization.

Some technical information, dispensing specifications and performanceparameters relating to certain embodiments of the S100 dispensing systemare presented in TABLE 3 below:

TABLE 3 sciFLEXARRAYER S100 Dispensing System Dimensions with min. 150 ×180 (2 portals) × 150 cm enclosure (L × W × H) Weight min. 500 kg PowerRequirements the machine runs on 400 V-500 V three-phase referencingReferencing System controlled via X, Y, Z stage and conveyer beltThroughput several 1000 per shift, approximately 1 array or sensor <10sec Dispensing mode aspirate/dispense mode using sciDROP technology; orbulk dispensing using sciSWIFT technology Source MTP, vessel or sciSWIFTcartridge Target carriers for 4 glass slide; other formats available asneeded or desired Options e.g. target/carrier feed-in and feed-out No.of portals up to 12 No. of dispense 1-12 per portal capillaries Minimumdistance of 9.0 mm dispense capillaries Dispense volume 100-500 pL perdroplet Typical spot size 120-250 μm Pitch (spacing) scaleable Dispensecontrol 2 CCD Cameras for XY correction X-Y Axis magnetic linear drivesAccuracy conveyer belts <±200 μm

U.S. Pat. No. 6,599,479 B1, the entirety of which is hereby incorporatedby reference herein, discloses a multi-channel dispensing head includinga plurality of micropipettes, each micropipette having an electricallyactuatable trigger device with a ground and signal terminal; and ashared carrier having a plurality of receptacles located in a one- ortwo-dimensional arrangement and sized and shaped to receive saidmicropipettes, each receptacle having a ground and signal contact,wherein the ground and signal contacts on the carrier are spaced apartin the direction of a longitudinal axis extending through the respectivemicropipettes and each of the ground and signal contacts on the carriercontacting the ground and signal terminals of the trigger devices,respectively. The dispensing head delivers liquid droplets on or intopredetermined locations of a target or substrate.

In some embodiments, U.S. Pat. No. 6,599,479 B1 provides a multichanneldispensing head in which micropipettes are arranged on a shared carrierin a two-dimensional or planar manner each with an electricallyactuatable trigger device, which has a ground and signal terminal, thecarrier having a ground or signal contact for each ground and signalterminal, wherein the ground and signal contacts on the carrier arearranged in two planes separated and electrically insulated from eachother. The contacts on the carrier are spaced apart relative to theaxial expansion (or longitudinal expansion) of the micropipettes. Thisconfiguration enables a greatly simplified design with a more compactmicropipette arrangement.

Liquid handling embodiments disclosed in U.S. Pat. No. 6,599,479 B1 makereference to a dispensing head with piezoelectrically actuatablemicropipettes, which are set up for the vertical release of microdropson substrates in the sub-microliter (μL) range. However, the patent(U.S. Pat. No. 6,599,479) contemplates the use of a wide variety ofmicroparticle placement devices with many types of trigger devices inwhich electrically actuated dispensers are arranged in rows or matrices,and the individual trigger devices of each dispenser are intended to beseparately actuatable. Moreover, the patent (U.S. Pat. No. 6,599,479)contemplates formats for micropipette arrangement, which can be appliedat any row length or matrix size for the vertical or horizontalmicrodrop or particle release.

FIG. 1C shows a schematic sectional view of a dispensing head, system orapparatus 410 in accordance with certain embodiments. The dispensinghead 410 comprises a group of micropipettes 420 (420 a, 420 b, . . . )that are attached to a shared carrier, gantry or arm 430, which can beadjusted with an x-y-z positioning device. Each micropipette 420 has apiezo element 421 as the trigger device with two control terminalscomprising a ground terminal 422 and a signal terminal (or: phaseterminal) 423. The micropipette 420 forms a load containing portion 424at the pipette tip, which goes into a carrier containing portion 425 ifneeded. The opposite end of the micropipette has a pressure line 426.Though FIG. 1C shows a linear array of micropipettes, dispense channelsor capillaries 420, the micropipettes can be efficaciously arranged inother manners (e.g., 2 or 3 dimensional arrays, non-linear arrays,staggered arrays, oblique or perpendicular arrays, arrays based on polaror cylindrical coordinates, combinations thereof, among others.)

The carrier 430 comprises at least one plate-shaped carrier element,which has receptacles 432 (432 a, 432 b, . . . ) for securing themicropipettes 420. In addition, the carrier 430 is provided withcontacts 434, 435 at two spaced, electrically isolated, essentially flatareas, which in the depicted example are formed by the surfaces 431, 433(or side surfaces) of the carrier element, each of these contactscomprising a ground contact 434 and a signal contact 435. The ground andsignal contacts 434, 435 are each electrically connected with the groundand signal terminals 422, 423 of the piezo elements 421. Finally,electronic components and devices for attaching and connecting them canbe provided on the carrier. To this end, the carrier is preferably aprinted circuit board itself. In particular, the complete supply anddemultiplexer electronics can be incorporated on the carrier.

An attachment device for holding the micropipette 420 is provided ateach receptacle 432 of the carrier element 431. The attachment device isdesirably detachable, so that individual micropipettes can be changedout. In one embodiment, the attachment device itself is formed by theground and signal contacts 434, 435, provided the latter are springelements, which act to retain the micropipettes 420 with the piezoelement 421 in the receptacle 432.

As indicated with reference to FIG. 1C, each micropipette 420 isprovided with a pressure line 426 which can simplify handling of amulti-channel dispensing head. In some embodiments, the pressure lines426 of all micropipettes are connected with a distributor which is alsosecured to the dispensing head. A pressure supply line leads from thedistributor to a fixed pressure device. The pressure device is providedto generate underpressures or overpressures for receiving carrierliquids, cleaning or stabilizing the pressure, which are conveyed by thedistributor arrangement to the pressure lines 426 (e.g., gas pressurelines). The distributor can be a multi-valve or a branching arrangement.In the multi-valve arrangement, a number of valves corresponding to thenumber of micropipettes are provided at the dispensing head. Themulti-valve arrangement desirably allows control of the pressure ofindividual micropipettes for charging or cleaning purposes. In thebranching arrangement, the pressure supply line opens into the numerouspressure lines 426 without valves.

Embodiments of the dispensing head 410 and associated components, andother arrangements as disclosed in U.S. Pat. No. 6,599,479 B1 offerseveral advantages. The multi-channel dispensing head (e.g. dispensinghead 410) has a desirably simplified design, which also permits asimplification of micropipette actuation depending on the specificmicropipette arrangement through the use of, for example, demultiplextechnology. In addition, the simplified structure is easier tomanipulate, and, hence, can be positioned more precisely. Moreover, thearrangement of micropipettes (e.g., on a shared carrier) enhancesoverall operation relating to an increase in the number of parallelprocessed substances, thereby desirably resulting in a correspondingtime savings. Also, the multi-channel dispensing head (e.g. dispensinghead 410) advantageously enables a substantially fully automatic andreproducible control of dispensing head positioning and micro-droprelease times based on predetermined program patterns, e.g., using acontrol computer.

In some embodiments, to dispense drops in the nanoliter range atechnology and product base as available from BioDot, Inc. of Irvine,Calif., U.S.A. is utilized to deliver reagents at rates up to about 20to about 50 parts or arrays per second using on-the-fly dispensingmethods to deliver volumes in the range from about 20 nanoliter (nL) orless to about 100 nanoliter (nL) or more using bulk dispensing. Incertain embodiments, on the fly dispensing modes are utilized to providea throughput in the range from about 20 to about 50 depositions persecond per dispenser, including all values and sub-ranges therebetween.In some embodiments, such as on the fly dispensing, the throughput is inthe range from about 20 to about 500 depositions per second perdispenser, including all values and sub-ranges therebetween.

In brief, the BioDot dispensing (and/or aspirating) system in accordancewith some embodiments, comprises a positive displacement syringe pump ordevice (or a direct current fluid source) hydraulically coupled or influid communication with a solenoid dispenser or actuator, and motioncontrol means or device(s) to provide relative motion between thedispensing/aspirating tip and the target(s)/source(s), as needed ordesired.

Any of these technologies, and many of the others taught or suggestedherein, can be efficaciously utilized to place drops on previouslydispensed spots or liquid drops in accordance with certain embodimentsof the invention. Advantageously, this capability offers new, high speedapproaches to the hybridization processes, and other assaying andquantitative development processes.

BioDot's U.S. Pat. Nos. 5,738,728, 5,741,554, 5,743,960, 5,916,524,6,537,505 B1, 6,576,295 B2, RE38,281 E, U.S. Patent ApplicationPublication Nos. US 2003/0211620 A1, US 2004/0072364 A1, US 2004/0072365A1, US 2004/0219688 A1, US 2005/0056713 A1, US 2006/0211132 A1, andEuropean Patent No. EP 1 485 204 B1, the entirety of each one of whichis hereby incorporated by reference herein, disclose dispensing (and/oraspirating) systems and methods which can be efficaciously utilized inaccordance with certain embodiments of the invention. All of thesepatent documents, as applicable, comprise a part of the present patentspecification/application.

U.S. Pat. Nos. 6,063,339, 6,551,557 B1, 6,589,791 B1, and U.S. PatentApplication Publication Nos. US 2002/0064482 A1, US 2003/0207464 A1, US2003/0215957 A1, US 2003/0228241 A1, the entirety of each one of whichis hereby incorporated by reference herein, disclose dispensing (and/oraspirating) systems and methods which can be efficaciously utilized inaccordance with certain embodiments of the invention. All of thesepatent documents, as applicable, comprise a part of the present patentspecification/application.

FIG. 2A shows a BioJet Quanti™ dispensing system or apparatus 450 inaccordance with certain embodiments. This quantitative non contacttechnology couples the BioDot “drop-on-demand” valve with a highresolution syringe pump to meter precise amounts of reagent.Incorporating the benefits of non-contact dispensing and the ability toprogram exact drop volumes, results in BioJet technology being aflexible and highly accurate technology.

The dispensing system 450 generally comprises a syringe 452 with aplunger 454 selectively communicable with a BioJet valve 456 and adispense tip 458 via a dispense line 460. The figure also shows a BioJetvalve connection 462. The syringe 452 is also selectively communicablewith a reagent or liquid source 464 via a feed line 466. The system 450dispenses droplets onto or into a target or substrate 468 which may beassociated with backing cards 470.

FIG. 2B shows a BioJet Plus™ dispensing system or apparatus 450′ inaccordance with certain embodiments. The proprietary BioJet Plustechnology was developed for high speed dispensing. The technologyinvolves (1) the coupling of a high speed micro solenoid valve with ahigh resolution syringe pump and (2) synchronization of the dispensesystem with the movements of the stage. The result is an extremely fastdispensing system which can deliver volumes from 20 nL to 4 μL in asingle drop. BioJet Plus can work in either an Aspirate/Dispense mode ora Bulk Dispense mode. The BioJet Plus system can be used to dispensebuffers, antibodies, enzymes or cells, among others. BioJet Plusdispensing is independent of the substrate allowing flexible dispensingto microtiter plates, glass slides or membranes. BioJet Plus systems areavailable from compact R&D systems to complete integrated manufacturingmodules.

The dispensing system 450′ generally comprises a syringe 452′ with aplunger 454′ selectively communicable with a BioJet Plus™ valve 456′ anda ceramic dispense tip 458′ via a dispense line 460′. The figure alsoshows a BioJet Plus™ valve connection 462′. The syringe 452′ is alsoselectively communicable with a reagent or liquid source 464′ via a feedline 466′. The system 450′ dispenses droplets onto or into a target orsubstrate 468′ which may be associated with sensor cards 470′.

In some embodiments, a tandem pump dispensing system is utilized byemploying two syringe pumps for a single dispense operation where thesyringes alternately fill and dispense to provide continuous flow forthe dispensing operation. (Some embodiments of such a configuration aredisclosed in U.S. Pat. No. RE38,281 E, the entirety of which isincorporated by reference herein.) The “Tandem Pump” configuration maybe used in conjunction with any of the applicable dispensing embodimentstaught or suggested herein. This desirably allows the use of small highresolution syringes in the range of 250 μL to be used. With thisconfiguration continuous dispensing can be achieved with no limitationsof the web length. In some embodiments, the “Tandem Pump” configurationis used for bulk dispensing on web based systems for both drop as wellas continuous lines. For example, an aerosol type of dispense nozzle(e.g. see U.S. Pat. No. 5,738,728) that uses pressurized air to atomizethe fluid passing through the nozzle can be utilized to create aquantitative spray format where a dot or line can be quantitativelygeneration on a continuous basis. In another example, the embodiments ofFIGS. 2A and 2B can employ a “tandem pump” configuration to dispensedrops at frequencies in the range of 20-1000 Hz to dispense non-contactdrops on a continuous base. The advantages include: providing theability to combine positive displacement dispensing with continuousoperation; and versatility in configuration to allow adaptability to arange of different dispensing methods and/or systems.

U.S. Pat. Nos. 6,063,339, 5,916,524, 5,738,728, 5,743,960 and 5,741,554,the entirety of each one of which is hereby incorporated by reference,disclose the concept of a reagent dispensing apparatus and method inwhich a positive displacement syringe pump is used in combination with aliquid dispenser, such as a solenoid valve dispenser or piezoelectricdispenser, to achieve improved dispensing operations. The syringe pumpmeters a predetermined quantity or flow rate of reagent to the dispenserto regulate the quantity or flow rate of liquid reagent dispensed.Simultaneously, an associated X, X-Y or X-Y-Z table is controlled so asto move a substrate in coordinated relation with the dispenser operationsuch that the reagent density can be controlled, for example, in termsof volume of reagent deposited per unit length of substratesubstantially independently of the particular flow characteristics ofthe liquid reagent or the particular operating parameters of thedispenser (within a given range).

Providing a positive displacement pump in series with the dispenseradvantageously allows the quantity or flow rate of reagent to becontrolled independently of the particular flow characteristics of theliquid being dispensed and/or the operating parameters of the particulardispenser. For example, the size of droplets formed by a dispenser canbe adjusted by changing the operating frequency (for a solenoid valve orpiezoelectric dispenser) or by adjusting the air pressure or exitorifice size (for an air brush dispenser) without affecting the flowrate of reagent. Also, the reagent flow rate can be controlled withoutsubstantial regard to the system operating parameters otherwise requiredto achieve stable dispensing operations. The quantity or flow rate ofreagent dispensed is controlled or regulated independently by thepositive displacement pump.

U.S. Patent Application Publication No. US 2004/0219688 A1, entitledMETHOD AND APPARATUS FOR HIGH-SPEED MICROFLUIDIC DISPENSING USING TEXTFILE CONTROL, the entirety of which is hereby incorporated by referenceherein, discloses the concept of a method and apparatus for dispensingreagents and other liquids onto a target or substrate and, inparticular, a method and apparatus for high-speed precision dispensing,controlled by input data from a user-defined text file, of multiplechemical or biological reagents with the ability to dispense a widedynamic range of dispense volumes in complex combinatorial patterns,ratios and arrays onto or into a high-density microwell plate, glassslide, receptive membrane, test strip, vial or other suitable target.

Certain embodiments relate to methods and systems for high-speedprecision dispensing and/or aspirating of microfluidic and/orsub-microfluidic quantities of reagents and other liquids. In someembodiments, the operation of the systems is controlled by data accessedfrom a customized user-defined text file. Advantageously, the use ofsuch text file control allows high-speed precision dispensing of one ormore reagents with a wide dynamic range of dispense volumes in complexcombinatorial patterns, ratios and arrays onto or into multiplepredetermined locations of a desired target or substrate. This isparticularly advantageous when a large number of permutations ofdifferent reagent and permutations of reagent volume ratios areinvolved. In some embodiments, the systems are operated in a highfrequency modulated mode to further improve accuracy and reliability.

European Patent No. EP 1 485 204 B1, the entirety of each one of whichis hereby incorporated by reference herein, discloses systems andmethods for dispersing or dispensing liquids or reagents below a fluidsurface using non-contact dispensing which can be efficaciously utilizedin accordance with certain embodiments of the invention.

Some embodiments relate generally to dispensing of fluid droplets and inparticular to methods and systems of dispersing, suspending or arrangingmicrofluidic and/or sub-microfluidic volumes of droplets of chemical,biological or other reagents or liquids below the surface of a cover orhost fluid using non-contact dispensing for creating an assay orreaction that produces a detectable signal or a by-product such as aharvestable protein crystal. Advantageously, evaporation of valuablereagents is substantially prevented or reduced. Another advantage, inthe case of miscible reagents, is that the drop velocities provide goodmixing. Yet another advantage is that, in the non-contact dispensingscheme, the nozzle or tip is not immersed into the host fluid, therebyfacilitating cleaning.

FIG. 2C is a simplified overview of a dispensing apparatus 508 inaccordance with certain embodiments. The dispensing apparatus 508 isparticularly adapted for automated high-speed precision dispensing (andaspirating) of liquids such as chemical and biological reagents, forexample, DNA, cDNA, RNA, proteins, peptides, oligonucletides, otherorganic or inorganic compounds, among others.

The dispensing apparatus 508 (FIG. 2C) generally comprises a dispensinghead or dispenser 528 having a valve or other dispensing means 604operated by an actuator, such as a solenoid. The dispenser 528 ishydraulically coupled or in fluid communication with a positivedisplacement pump 520 for metering precise quantities of fluid or liquid530 to or towards the dispenser 528. The dispenser 528 is mounted on orin association with an X-Y table or gantry 510.

As shown in FIG. 2C, a substrate or target 511 is mounted on a carrierplatform, table or carriage 512 to receive reagent or liquid dispensedfrom the dispenser 528. The target 511 can comprise one or moremicrotiter plates, glass slides, receptive membranes, test strips, orother suitable porous or non-porous targets such as one or moresingle-well receptacles, vials or tubes. The microtiter plates can beconfigured in 96, 384, 1536 and 2080 well plate formats, among otherconfigurations.

Those skilled in the art will appreciate that the X-Y table 510 (FIG.2C) may include one or more position stepper motors 523, 524 or thelike, which are operable to move either the dispenser 528 and/or thecarrier platform or table 512 relative to one another in the X, X-Y orX-Y-Z directions, as indicated in the drawing. Alternatively, or inaddition, one or more suitable robot arms may be efficaciously used, asneeded or desired, to provide controlled relative motion between thedispenser 528 and the target substrate 511 and/or other components orassociated components of the apparatus 508.

Though FIG. 2C shows only a single dispenser 528, in other preferredembodiments and as discussed further below, it is contemplated thatmultiple dispensers in linear (1×N) or two-dimensional (M×N) arrays areused. These may be provided and operated either in parallel or inanother coordinated fashion, as desired. It should be understood thatany discussion herein with specific reference to the single dispenserembodiment is substantially equally applicable, with possiblemodifications as apparent to the skilled artisan, to multiple dispenserseach connected to respective pumps or a single pump.

The positive displacement pump 520 (FIG. 2C) preferably comprises asyringe pump though other direct current (DC) fluid sources may be usedwith efficacy. The syringe pump 520 is hydraulically coupled to or influid communication with a fluid reservoir 516 through a first one-waycheck valve or open-close valve 545 a. The syringe pump 520 draws fluid530 from the fluid reservoir 516 and provides it to the dispenser 528through a second check valve or open-close valve 545 b on a supply lineor feedline 550, as shown in FIG. 2C.

The syringe pump 520 (FIG. 2C) has a movable piston 518 within a syringebarrel 762. The syringe pump 520 is operated by a syringe pump driver542 comprising, for example, a stepper motor and an associated leadscrew, for extending and retracting the piston 518 within the syringebarrel 762. Those skilled in the art will readily appreciate that whenthe piston 518 is retracted, fluid 530 is drawn from the reservoir 516into the syringe pump 520. When the piston 518 is again extended, fluid530 is forced to flow from the syringe barrel 762 into the dispenser 528via the supply tube 550, whereupon it is ejected by the dispenser 528onto or into the target substrate 511 in the form of droplets 531 or aspray pattern.

In one embodiment, the fluid or liquid 530 (FIG. 2C) comprises thereagent that is dispensed onto or into the target 511. That is thesystem (reservoir 516, pump barrel 762, dispenser 528 and otherconnection lines) is filled with the reagent 530 to be dispensed. Thisset-up is particularly advantageous when relatively large quantities ofthe same reagent are to be dispensed.

In another embodiment, the fluid or liquid 530 (FIG. 2C) comprises asystem fluid or backing reagent, such as distilled water, and thedispensing apparatus 508 operates in a “suck-and-spit” mode. In thisembodiment, the dispenser 528 is used to aspirate a predetermined amountof fluid, liquid or reagent from a source receptacle or microtiter plateand the like and then dispense the aspirated reagent onto or into thetarget 511. As the skilled artisan will appreciate, reagent is aspiratedby retracting or decrementing the pump piston 518 with the valve 545 bopen to create a reduced pressure or partial vacuum to draw sourcereagent into the dispenser 528 via a suitable tip or nozzle thereon.

A controller 514 (FIG. 2C) oversees operation of the pump 520, X-Y table510 (or X, or X-Y-Z table) and the dispenser 528, among other associatedcomponents. The controller 514 coordinates and controls the motion ofeach of the stepper motors 523, 524, and the syringe pump driver 542, aswell as the opening and closing of the dispensing valve 604 to preciselydispense an amount of reagent at one or more predetermined location(s)on or in the target substrate 511. The controller 514 also controls andcoordinates aspiration of source reagent, as and if needed.

A computer software program is interfaced with the controller 514 (FIG.2C) to guide dispensing (and/or aspirating) for different modes ofoperation and different applications. Preferably, a user-defined textfile is created, for example, from a spreadsheet of values or template,with lists of numbers of user-defined dispense volumes of one or morereagents and corresponding coordinates of the dispense (and/or aspirate)operation. The controller 514 uses this text file data in cooperationwith the software program to precisely control and coordinate theoperation of the dispensing apparatus 508.

Advantageously, the use of such text file control allows high-speedprecision dispensing of one or more reagents with a wide dynamic rangeof dispense volumes in complex combinatorial patterns, ratios and arraysonto or into multiple predetermined locations of a desired target orsubstrate. This is particularly advantageous when a large number ofpermutations of different reagent and permutations of reagent volumeratios are involved. In such cases, typically, more than one dispenser(see FIGS. 2D and 2E) or a manifold system (see FIG. 2F) or acombination thereof is utilized to facilitate process efficiency. Thesemultiple dispensers can be operated in parallel or in synchronouscoordination.

FIG. 2D is a simplified view of a dispensing apparatus 508 a comprisinga plurality of dispensers 528. As has been described above in referenceto FIG. 2C, each dispenser 528 is connected to a respective pump 520 (inFIG. 2D, the pumps 520 are part of a pump bank 520 a and a reservoirbank 516 a comprises the reservoirs 516). A single reagent may bedispensed by all of the dispensers 528 or multiple reagents, as neededor desired. Moreover, reagent(s) can be first aspirated and thendispensed, as discussed above.

Still referring in particular to FIG. 2D, relative motion is providedbetween the substrate or target 511 and the dispensing channels 528. Thedispensers 528 and/or the platform 512 are movable in the X, X-Y orX-Y-Z directions to allow for precision dispensing at predeterminedlocations. Multiple targets 511 may be placed on the table 512, asneeded or desired. The dispensers 528 can be independently moved ortogether in the form of a dispense head comprising multiple dispensechannels 528 paced from one another by predetermined distance(s).Moreover, the dispensers 528 can be individually (serially orsequentially) operated or substantially simultaneously (parallely) or acombination thereof, as needed or desired. A central or main controller,possibly in conjunction with sub-controllers, is used to control andcoordinate the actuations of the pumps 520, dispensers 528 and relativemovement between the target 511 and dispense channels 528.

FIG. 2E is a schematic view of a dispensing apparatus 508 b comprising aplurality of dispensers 528. In general, the dispensing apparatusesdescribed herein can comprise one or more dispensers 528 arranged in awide variety of configurations such as linear (1×N), two-dimensional(M×N) or even three-dimensional (M×N×K) arrays. It should be noted thatthe array or collection of dispensers or dispenser heads 528 may bereferred to as a “dispensing head” comprising multiple dispense channelsor capillaries 528.

FIG. 2F is a simplified view of a dispensing apparatus 508 c comprisinga manifold 509 connected to a plurality of dispensers 528. The manifoldgenerally comprises a main supply line 513 in fluid communication(hydraulically coupled) with a plurality of independent channels 515each of which is in fluid communication (hydraulically coupled) with arespective one of the dispensers 528. A positive displacement syringepump 520 is in fluid communication (hydraulically coupled) with themanifold 509 via the feedline 550. Reagent(s) can be first aspirated andthen dispensed or a single reagent may fill the system, as discussedabove.

Still referring in particular to FIG. 2F, relative motion is providedbetween the substrate or target 511 and the dispensing channels 528. Thedispensers 528 and/or the platform 512 are movable in the X, X-Y orX-Y-Z directions to allow for precision dispensing at predeterminedlocations. Multiple targets 511 may be placed on the table 512, asneeded or desired. The dispensers 528 are in the form of multipledispense channels spaced from one another by predetermined distance(s).More than one manifold may be utilized, as needed or desired.

The dispensers 528 (FIG. 2F) can be individually (serially orsequentially) operated or substantially simultaneously (parallely) or acombination thereof, as needed or desired. A linear (1×N) ortwo-dimensional (M×N) array of dispensers 528 may be used with efficacy.A central or main controller 514 is used to control and coordinate theactuations of the pump 520, dispensers 528 and relative movement betweenthe target 511 and dispense channels 128. Certain embodiments of amulti-channel aspirate-dispense system comprising a manifold aredescribed in U.S. Patent Application Publication No. US 2003/0215957 A1,entitled MULTI-CHANNEL DISPENSING SYSTEM, the entirety of which ishereby incorporated by reference herein.

Advantageously, and as shown in FIG. 2F, the use of a manifold 509allows only one pump 520 to meter fluid to and from a plurality ofdispensers 528. Desirably, this saves on cost. Moreover, balanced andcontrolled output can be achieved by adjusting the frequency and/or dutycycle of one or more of the dispensers 528 to compensate for anyvariations in flow resistances between channels.

FIG. 2G is a cross-sectional view of one embodiment of a solenoid valvedispensing head 128 for use, as applicable, with the dispensing (and/oraspiration) systems as described herein. Solenoid valve dispensers ofthe type shown in FIG. 3A are commonly used for ink-jet printingapplications and are commercially available from sources such as The LeeCompany of Westbrook, Conn. Other suitable drop-on-demand dispensers andvalves may be efficaciously used, as needed or desired.

The drop-on-demand dispenser 528 generally comprises a solenoid portion602, a valve portion 604 and a tube, capillary, tip or nozzle portion605. The solenoid portion 602 and the valve portion 204 in combinationcan be termed a drop-on-demand valve, a solenoid-actuated valve or amicro-solenoid valve 603.

The solenoid portion 602 comprises an electromagnetic coil or winding606, a static core 638 and a movable plunger 640. The static core 638and movable plunger 640 are disposed within a hollow cylindrical sleeve641 and are preferably spaced at least slightly away from the innerwalls of the sleeve 641 so as to form an annular passage 642 therebetween through which the reagent 530 or other liquid to be dispensedmay flow. The static core 638 and movable plunger 640 are preferablyformed of a ferrous or magnetic material, such as an iron alloy, and areseparated by a small gap 644. Those skilled in the art will appreciatethat when the solenoid coil 606 is energized, for example by a currentor voltage, a magnetic field is created which draws the plunger 640upward toward the static core 638, closing the gap 644 and opening thevalve 634.

The valve portion 604 comprises a valve seat 652, having an orificeopening 654, and a stopper 656 having a valve face 658 adapted to sealagainst the valve seat 652. The stopper 656 is in electro-mechanicalcommunication with the plunger 640 and is spring biased toward the valveseat 652 via coil spring 660. Again, those skilled in the art willreadily appreciate that as the plunger 640 moves up and down, the valve234 will open and close, accordingly, hence providing selective fluidcommunication with the tip 605. Moreover, each time the valve 234 opensand closes, a volume of liquid is allowed to escape through the valveorifice 654. This, in conjunction with the metering of fluid by the pump520, forms an energy pulse or pressure wave which causes a droplet ofliquid to be ejected from the exit orifice 661 of the nozzle tip 659.

As indicated above, preferably, the pump 520 (see, for example, FIG. 2C)is a positive displacement pump and is provided in series with thesolenoid valve dispenser 528. Configuring the dispensing system in thismanner has the benefit of forcing the solenoid valve dispenser 528 toadmit and eject a quantity and/or flow rate of reagent as determinedsolely by the positive displacement pump 520, with which it ishydraulically in series. For example, the syringe pump could beinstructed to deliver a flow rate of 1 microliter per second of reagentto the solenoid valve dispenser 528 at a steady rate. As the valvestopper 556 is opened and closed at a given frequency and duty cycle aseries of droplets are formed which will exactly match the desired flowrate. The syringe pump acts as a forcing function for the entire system,ensuring that the desired flow rate is maintained regardless of the dutycycle or frequency of the dispensing valve.

Advantageously, within a certain operating range the frequency and/orvelocity of the droplets can be adjusted without affecting the flow rateof reagent simply by changing the frequency and/or duty cycle of theenergizing pulses 582 (FIG. 2C) provided to the solenoid valve dispenser528. Of course, there are physical limitations of valve open time orduty-cycle necessary to achieve stable droplet formation. If the opentime is too short relative to the flow rate, the pressure will increaseand possibly prevent the valve dispenser 528 from functioning properly.If the open time is too long relative to the flow rate, then dropformation may be impaired or may not be uniform for each open/closecycle. Nevertheless, for a given flow rate of reagent 530 provided bythe syringe pump 520 there will be a range of compatible frequenciesand/or valve open times or duty-cycles in which stable dispensingoperations may be achieved at the desired flow rate and droplet size.This range may be determined experimentally for a given production setup.

Certain embodiments of a solenoid actuated dispenser are described inU.S. Pat. No. 6,537,505 B1, entitled REAGENT DISPENSING VALVE, theentirety of each one of which is hereby incorporated by referenceherein.

Those skilled in the art will recognize that other types of dispensersand valve actuation devices exist and may be used with efficacy. Thesemay include, for example, but are not limited to piezoelectricdispensers, fluid impulse dispensers, heat actuated dispensers, airbrush dispensers, and the like.

FIG. 2H shows a cross-sectional view of a piezoelectric dispenser 528′which also has advantageous use in accordance with certain embodimentsof the invention. The piezoelectric dispenser 528′ generally comprises acapillary tube 670 made of glass or other suitable material and apiezoelectric constrictor 672 disposed around the capillary tube 670, asshown. The capillary tube 670 has a nozzle portion 674 of a reduceddiameter. When the capillary tube 670 is constricted by thepiezoelectric constrictor 672, droplets 676 are formed at the exitorifice 678 of the nozzle portion 674. Advantageously, the dynamics ofthe piezoelectric dispenser 628′ are such that it may be able to operateat even higher frequencies and shorter duty cycles than typical solenoidvalve dispensers, resulting in even smaller droplets 676. Operation ofthe piezoelectric dispenser 628′ in terms of adjusting droplet size,frequency, velocity and flow rates is substantially the same or similarto that described in connection with the solenoid valve dispenser 628 ofFIG. 2G and, therefore, will not be repeated here.

FIGS. 2I, 2J and 2K show different views of a non-contact dispensingcapillary tip or tube 1000 having features and advantages in accordancewith certain embodiments of the invention. The dispensing tip 1000 maybe incorporated into any of the dispensing systems taught or suggestedherein, as applicable. Embodiments of such tips are disclosed in

U.S. Pat. No. 6,551,557 B1, entitled TIP DESIGN AND RANDOM ACCESS ARRAYFOR MICROFLUIDIC TRANSFER, the entirety of which is hereby incorporatedby reference herein.

In the illustrated embodiment of FIGS. 2I-2K, the tip 1000 is generallycylindrical in shape and comprises a non-tapered upper portion or shank1002 with an upper end 1003, a tapered lower portion/outer surface 1004with a lower end 1005 and an inner lumen or through cavity 1006. Theinner lumen 1006 is generally cylindrical in shape with a top opening1008, a non-tapered upper portion 1010, and a tapered lowerportion/inner surface 1012 to form a nozzle 1014 having an orifice oropening 1016. Advantageously, the outer taper 1004 leads to lessaccumulation of fluid on the tip outer surface, for example, duringaspiration. Also, advantageously, the inner taper 1012 is a desirableshape for capillary action, and reduces fluid mixing during aspirationand reduces the precipitation of gaseous bubbles within the fluid duringaspirate-dispense operations.

Optionally, as shown in FIG. 2I, the tip 1000 may further include agenerally circumferential groove, slot or notch 1018 on the non-taperedupper portion 1002. The slot 1018 is generally V-shaped. The notch 1018advantageously provides an easy break point in the case of accidentalhard or jarring contact between the tip 1000 and a contacting surface ofthe fluid source or target.

Preferably, the tip 1000 is fabricated from a ceramic material, and morepreferably, from alumina. Advantageously, the ceramic material provideschemical inertness since alumina is inert to most chemical solvents.Moreover, the ceramic material provides robustness, and hence canwithstand extreme mechanical stress. In other embodiments, the tip 1000can be fabricated from a wide variety of materials with efficacy such asmetals, alloys, and plastics, as required or desired, giving dueconsideration to the goals of providing chemical inertness androbustness.

In one embodiment, the outer surface 1019 (FIG. 2I) of the tip 1000 iscoated with a thin film or coating that is not only chemically inert andmechanically robust but is also hydrophobic to most fluids such asaqueous reagents, DMSO, and other common solvents. The film helps inkeeping the tip 1000 dry and also improves the microfluidic orsub-microfluidic transfer. Preferably, the film comprises awear-resistant material so that it has an enhanced lifetime. Suitablefilms or coatings include silicon nitride, silicon carbide, titaniumnitride, among others. The film or coating can be applied by a varietyof methods such as plasma deposition and sputtering, among others, as isknown in the art. A suitable hydrophobic coating may also be applied toselected portions of the inner surface 1021 of the tip 1000, as neededor desired.

The tip 1000 may be dimensioned in a wide variety of manners withefficacy, as required or desired, giving due consideration to the goalsof providing reliable and repeatable microfluidic and sub-microfluidictransfer of fluid. In one embodiment, the tip 1000 has a length of 16 mmand an internal volume of about 20 microliters (μL). In someembodiments, the inner diameter at the nozzle end of the tip 1000 is inthe range from about 20 to 180 microns (μm) and the outer diameter is inthe range from about 50 to 400 μm or more. In other embodiments, theinner diameter at the nozzle end of the tip 1000 is in the range fromabout 100 to 300 μm and the outer diameter is in the range from about400 to 900 μm.

Referring in particular to FIGS. 2C and 2L, the pump 520 is preferably ahigh-resolution, positive displacement syringe pump hydraulicallycoupled to the dispenser 528. Alternatively, pump 520 may be any one ofseveral varieties of commercially available pumping devices for meteringprecise quantities of liquid. A syringe-type pump 520, as shown forexample in FIG. 2C, is preferred because of its convenience andcommercial availability. A wide variety of other direct current fluidsource means may be used, however, to achieve the benefits andadvantages as disclosed herein. These may include, without limitation,rotary pumps, peristaltic pumps, squash-plate pumps, and the like, or anelectronically regulated fluid current source.

As illustrated in FIG. 2L, a suitable syringe pump 520 generallycomprises a syringe housing 762 of a predetermined volume and a plunger518 which is sealed against the syringe housing by O-rings or the like(not shown). The plunger 518 mechanically engages a plunger shaft 766having a lead screw portion 768 adapted to thread in and out of a basesupport (not shown). Those skilled in the art will readily appreciatethat as the lead screw portion 768 of the plunger shaft 766 is rotatedthe plunger 518 will be displaced axially, forcing reagent 530 from thesyringe housing 762 into the exit tube 770. Any number of suitablemotors or mechanical actuators may be used to drive the lead screw 768.Preferably, a pump driver 542 including a stepper motor (FIG. 2C) orother incremental or continuous actuator device is used so that theamount and/or flow rate of reagent 530 can be precisely regulated.

Several suitable syringe pumps are commercially available. One suchsyringe pump is the Bio-Dot CV1000 Syringe Pump Dispenser, availablefrom BioDot, Inc. of Irvine, Calif. This particular syringe pumpincorporates an electronically controlled stepper motor for providingprecision liquid handling using a variety of syringe sizes. The CV1000is powered by a single 24 DC volt power supply and is controlled via anindustry-standard RS232 or RS485 bus interface. The syringe pump mayhave anywhere from 3,000-24,000 steps, although higher resolution pumpshaving 48,000-192,000 steps or more may also be with efficacy. Higherresolution pumps, such as piezoelectric motor driven pumps, may also beused to provide even finer resolutions as desired.

The lead screw 768 (FIG. 2L) may optionally be fitted with an opticalencoder or similar device to detect any lost steps. Alternatively, thelead screw of the metering pump can be replaced with a piezoelectricslide to provide both smaller volume increments and also fasteracceleration/deceleration characteristics. Multiple syringe pumps mayalso be used in parallel, for example, for delivering varyingconcentrations of reagent 530 and/or other liquids to the dispenser orfor alternating dispensing operations between two or more reagents. Thiscould have application, for instance, to ink jet printing using one ormore colored inks or liquid toners.

Syringe size may vary from less than 50 microliters (μL) to 50milliliters (mL), or more as needed. The minimum incrementaldisplacement volume of the pump will depend on the pump resolution andsyringe volume. For example, for a syringe housing volume of 50 μL and192,000 step resolution pump the minimum incremental displacement volumewill be about 0.260 nanoliters (nL). Minimum incremental displacementvolumes from about 0.25 nanoliters to about tens of milliliters (mL) arepreferred, although higher or lower incremental displacement volumes mayalso be used while still enjoying the benefits disclosed, taught orsuggested herein.

Of course, a wide variety of other positive displacement or “directcurrent” fluid sources may also be used to achieve the benefits andadvantages as disclosed herein. These may include, for example andwithout limitation, rotary pumps, peristaltic pumps, squash-plate pumps,pumps incorporating hydraulic or electronic feedback control and thelike.

In some embodiments, one or more pressure sensors 551 are provided inconjunction with the aspirate-dispense apparatuses 508 (FIG. 2C), 508 a(FIG. 2D), 508 b (FIG. 2E) and 508 c (FIG. 2F) to monitor the systempressure and provide diagnostic information about various fluid and flowparameters within the hydraulic system. The one or more pressure sensors551 are provided at appropriate locations on the respective systems. Inone embodiment, the pressure sensors 551 are placed intermediate thesyringe pump(s) 520 and the dispenser(s) 528, such as on the feedline550 (see, for example, FIG. 2C). Alternatively, or in addition, thepressure sensor(s) 551 can be situated at the dispenser(s) 528 such ason the valve portion(s) 604.

It should be noted that for purposes of brevity of disclosure some ofthe discussion here refers to a single pump-dispenser apparatus. Ofcourse, it should be understood that this can be suitably extrapolatedto include operation of the embodiments of arrays of pump-dispensersystems, for example, the systems of FIGS. 2D and 2E. Moreover, and asone of ordinary skill in the art will appreciate, it is furtherextendable with some modifications to manifold systems, for example, themanifold dispensing system of FIG. 2F.

Referring in particular to FIG. 2C, the skilled artisan will recognizethat the hydraulic coupling between the pump 520 and the dispenser 528of the aspirate-dispense system 508 provides for the situation where theinput from the pump 520 exactly equals the output from the dispenser 528under steady state conditions. Therefore, the positive displacementsystem uniquely determines the output volume of the system while theoperational dynamics of the dispenser 528 serve to transform the outputvolume into ejected drop(s) having size, frequency and velocity.

It has been discovered, however, that within the system there exists anelastic compliance partly due to the compliance in the delivery tubingand other connectors and components, and partly due to gaseous airbubbles that may have precipitated from air or other gases dissolved inthe system and/or source fluid. As a result of this elastic compliance,initial efforts to dispense small quantities of fluid resulted ingradually overcoming the system compliance and not in dispensing fluidor reagent. Once this elastic compliance was overcome, a steady statepressure was found to exist and complete dispensing occurred thereafter.

A discussion of the theoretical predicted behavior and theoretical flowmodels relating to positive displacement dispensing and aspiratingsystems can be found in U.S. Patent Application Publication No. US2003/0207464 A1, entitled METHODS FOR MICROFLUIDIC ASPIRATING ANDDISPENSING, U.S. Patent Application Publication No. US 2003/0215957 A1,entitled MULTI-CHANNEL DISPENSING SYSTEM, and U.S. Pat. No. 6,589,791B1, entitled STATE-VARIABLE CONTROL SYSTEM, the entirety of each one ofwhich is hereby incorporated by reference herein.

Thus, by providing a positive displacement pump 520 (FIG. 2C) in serieswith a dispenser 528 (FIG. 2C) has the benefit of forcing the dispenser528 to admit and eject a quantity and/or flow rate of reagent asdetermined solely by the positive displacement pump 520 for steady stateoperation. In essence, the syringe pump 520 acts as a forcing functionfor the entire system, ensuring that the desired flow rate is maintainedregardless of the duty cycle, frequency or other operating parameters ofthe dispensing valve, such as the solenoid-actuated valve 528 (FIG. 2G).With such configuration and at steady state operation one does notreally care what the pressure in the system is because it adjustsautomatically to provide the desired flow rate by virtue of having apositive displacement or direct current fluid source as a forcingfunction for the entire system.

However, this does not address the situation of latent and/or transientpressure variations, such as associated with initial start-up of eachdispense and aspirate function. In particular, it has been discoveredthat the pressure in the system is of critical concern for non-steadystate operation involving aspirating or dispensing of microfluidicquantities, typically greater than about 1 nanoliter (nL) and less thanabout 50 microliters (μL), of liquid reagents or other fluids.Specifically, for an aspirate function it has been discovered that asystem pressure close to or below zero is preferred, while for adispense function it has been discovered that a finite and positivepredetermined steady state pressure is preferred.

The transitions between various modes (aspirate, dispense, purge/wash)and/or flow rates or other operating parameters can result in pressuretransients and/or undesirable latent pressure conditions within thepositive displacement dispense/aspirate system. Purge and wash functionsusually entail active dispensing in a non-target position. In somecases, when the same reagent is to be aspirated again, severalaspirate-dispense cycles can be performed before executing a purge orwash function. Also, sometimes a purge function may have to be performedduring a dispense function, for example, to alleviate clogging due tothe precipitation of gaseous bubbles within the system and/or sourcefluid. Moreover, the accumulation of these bubbles can change the systemcompliance over time, and hence the desired optimum dispensing pressure.

For example, line 910 in FIG. 2M illustrates transient dispense effectscaused by initial start-up of a dispensing system 508 (FIG. 2C) in whichno pressure compensation scheme is utilized. The x-axis 903 representsthe dispense number or number of dispenses and the y-axis 902 representsthe dispense volume, in nanoliters (nL) of each droplet or dropletsdispensed. Line 914 in FIG. 5 represents the target dispense volume of100 nL.

As can be seen by the data of FIG. 2M, the non-pressure compensated(non-steady state) dispensed volume represented by line 910 issubstantially smaller than the target dispense volume of 100 nL (line914) since the system pressure at start-up is substantially lower thanthe desired steady state and/or predetermined pressure. The non-pressurecompensated dispense volume (line 910) can be lower by a factor of aboutten compared to the target dispense volume (line 914). Moreover, evenafter 23 dispenses (see FIG. 2M) the dispensed volume (line 910) isstill below the target volume (line 914).

Line 912 represents a series of about 100 nL dispenses performed inaccordance with one embodiment, wherein an optimized pressurizing (300steps of the syringe plunger 518—shown in FIGS. 2C and 2L) is performedprior to dispensing, that is, with the valve 604 (FIGS. 2C and 2G)closed. The pressure compensation scheme provides dispense volumes (line912) which are in substantially close conformity with the targetdispense volume (line 914) of 100 nL. Under-pressurization (200 steps ofthe syringe plunger 518), as illustrated by line 916, can result indispense volumes that are undesirably less than the target dispensevolume 914. Similarly, as illustrated by line 918, over-pressurization(400 steps of the syringe plunger 518) can result in dispense volumesthat are undesirably more than the target dispense volume 914.

Certain embodiments of pressure compensation or adjustment, for example,prior to dispense and aspirate functions, are described in U.S. PatentApplication Publication No. US 2003/0207464 A1, entitled METHODS FORMICROFLUIDIC ASPIRATING AND DISPENSING, U.S. Patent ApplicationPublication No. US 2003/0215957 A1, entitled MULTI-CHANNEL DISPENSINGSYSTEM, and U.S. Pat. No. 6,589,791 B1, entitled STATE-VARIABLE CONTROLSYSTEM, the entirety of each one of which is hereby incorporated byreference herein.

In brief, to set the system pressure to a predetermined and/or steadystate dispense pressure, the syringe plunger 518 (FIGS. 2C and 2L) istypically incremented (or possibly decremented) by a predeterminedamount to build up (or reduce) pressure, as described above inconnection with FIG. 2M. Similarly, to set the pressure to apredetermined and/or steady state aspirate pressure, the syringe plunger518 (FIGS. 2C and 2L) is typically decremented (or possibly incremented)by a predetermined amount. Of course, pre-dispenses of reagent or systemfluid in a waste position may be performed to raise or lower the systempressure, as needed or desired.

One or more pressure sensors, such as the pressure sensor(s) 551 (FIGS.2C-2F) are used to monitor the system pressure and ensure that thecorrect operational pressure(s) are achieved. Any one of a number ofcommercially available pressure sensors may be efficaciously used. Thepressure sensors 551 are preferably differential type devices.

The desired steady state dispense pressure can be estimated from flowresistances and/or prior steady state pressure measurements or transientpressure measurements. A number of parameters can affect the selectionof this pressure, including the desired droplet volume and systemcompliance, among other fluid, flow, system and operational parameters.

Some embodiments of methods for estimating this steady state dispensepressure are described in U.S. Patent Application Publication No. US2003/0207464 A1, entitled METHODS FOR MICROFLUIDIC ASPIRATING ANDDISPENSING, U.S. Patent Application Publication No. US 2003/0215957 A1,entitled MULTI-CHANNEL DISPENSING SYSTEM, and U.S. Pat. No. 6,589,791B1, entitled STATE-VARIABLE CONTROL SYSTEM, the entirety of each one ofwhich is hereby incorporated by reference herein.

The steady state pressure can also be estimated from previouslyformulated parametric tables or charts based on one or more fluid,system, flow and operational parameters. Regression analysis techniquesmay be used to estimate the optimum dispense pressure. Alternatively, orin addition, the dispense pressure may be predetermined for a givenproduction set-up.

In some embodiments, the aspirate-dispense systems disclosed herein areconfigured to minimize the formation and accumulation of gaseous bubbleswithin the fluid residing in the system, and particularly in thedispensers 528 (FIGS. 2C-2F), feedline 550 and manifold 509 (FIG. 2F).For example, to minimize bubble formation, the system components beconfigured such that the fluid movements within the system avoid sharplocal pressure drops, and hence gaseous bubble precipitation.Additionally, the components may be configured such that none or few“dead spots” are encountered by the fluid, thereby discouraging bubbleaccumulation within the system. These configurations can utilizesuitably tapered inner cavities or lumens within the valve portion 604,tip 605 and/or nozzle 659 to provide relief from gaseous bubbleprecipitation and/or “dead spots.”

In one embodiment, a suitably configured bubble trap (not shown) isprovided in fluid communication with the dispenser 528 (see, forexample, FIG. 2C). The trap encourages the migration of gaseous bubblesto collect within the trap and prevents undesirable bubble accumulationwithin the aspirate-dispense system.

In some embodiments, the dispensing operation takes place on-the-fly,that is without stopping the motion of the X-Y table (see U.S. Pat. No.6,063,339, incorporated by reference herein). To accommodate thison-the-fly dispensing without compromising accuracy, precision orrepeatability, the controller 514 calculates a phase adjustment for eachdispense cycle. The phase adjustment is such as to advance (or retard)the timing of the valve opening and closing so that the dispenseddroplet of reagent lands at the desired location on the substrate 511(or at a desired offset location), taking into account its anticipatedtrajectory.

Those skilled in the art will recognize that the magnitude of thenecessary or desired phase adjustment will depend, among other things,on a number of system input and output parameters and behavioralcharacteristics, including the desired drop offset (if any), thevertical distance between the dispenser nozzle 605 and the surface ofthe substrate 511, the velocity and/or acceleration of the dispenser 528and/or the substrate 511 relative to one another, the velocity of thedispensed droplets, ambient temperature and humidity, and othercontrolled and/or uncontrolled factors. While certain of theseparameters or characteristics can be isolated and studied such thattheir impact on the necessary phase adjustment is fairly predictable,other parameters or characteristics can neither be isolated norpredicted. It is however contemplated, that precise phase adjustmentscan be determined experimentally for a given production set up eitherbefore or during production such that a high degree of accuracy,precision and repeatability is attained during long production runs.

In some embodiments, a modulated mode of valve operation is utilized. Asdiscussed above, the syringe positive displacement and solenoid valve603 combination results in the syringe pump 520 determining the dropvolume and the solenoid valve aiding in the ejection of a drop from thedispense channel nozzle 659 (FIG. 2G). The modulation mode of operationtakes place when the solenoid drive current for open/close of the valve603 is driven at higher frequencies than allowed for a full open andclose situation. In this case, the valve plunger face 658 does not sealagainst the valve seat 652 but oscillates in the open position. Thisoscillation energy further facilitates the ejection of the fluid fromthe tip 605 and/or nozzle 659 through the orifice 661. The ejectionformat can be in the form of a continuous jet with volume oscillationsto individual drops. This mode of operation can typically be operated atmuch higher frequencies compared to the “burst” mode since the valvedoes not fully close. For example, theses frequencies can be in therange of about 6000 Hz.

The modulation mode can advantageously provide high speed dispensing offluid using small drop sizes. This provides a robust and accuratedelivery of fluid as compared to some lower frequency operations. Thismethod also allows for selection of parameters that eliminates the needfor pressure adjustment to achieve steady state dispensing betweendesired droplet volume changes. The modulation mode provides robust andaccurate delivery of single drops over a wide range of ejected dropvolumes, ranging from about 2 nL or less to over 100 nL.

It will be appreciated that any of the dispensing (and aspirating)systems taught or suggested herein can employ a number of optionalfeatures with efficacy, as needed or desired. The include, withoutlimitation: humidity control; cooling unit(s); clean room enclosure(s);camera(s); software options; degasser(s) (e.g., helium vacuum, in line);vacuum pump(s); wash station(s); vision system(s); and barcodereader(s).

U.S. Patent Application Publication No. US 2005/0056713 A1, the entiretyof which is hereby incorporated by reference herein, discloses heliumdegassing methods and systems. In certain embodiments, such a method isused to degas the fluids utilized in connection with the dispensingsystems disclosed herein. The method generally comprises pressurizing areservoir containing a reagent to a degassing high first pressure byproviding a static pressure from a helium source over the reagent todegas the reagent. The first pressure in the reservoir is reduced to alow second pressure. The reservoir is vented to ambient conditions. Apump connected to the reservoir is operated to draw the reagent from thereservoir into the pump. A tip having a dispense nozzle and a throughlumen is provided with the tip being connected to the pump. Apredetermined quantity of the reagent is metered from the pump to thetip to dispense one or more droplets of the reagent from the nozzle ontoor into a target.

U.S. Patent Application Publication No. US 2003/0228241 A1, the entiretyof which is hereby incorporated by reference herein, describes anapparatus for liquid sample handling which has efficacy in conjunctionwith some of the liquid dispensing and aspirating embodiments disclosedherein. The apparatus generally comprises a plurality of hollowcapillaries, a housing which retains the capillaries in their desiredorientation and means to effect sample removal from the capillaries.Each capillary is open at both ends and has a defined internal volume.On contact of an open end of the capillary with a sample a definedvolume of sample is drawn up into the capillary by capillary action. Thecapillaries can be arranged in a one-dimensional array or atwo-dimensional array. Pressurized gas is provided by means of a controlvalve and suitable pipework or through an orifice to achieve dropletdispensing.

Some Embodiments of Array Features and Details Array Density

For some embodiments, the expected or typical range of spots per arrayfor diagnostic applications is in the range from about 10 to about 3000.In certain embodiments, with the largest number of applications for highvolume diagnostics, the expected or typical range of spots per array isin the range from about 100 to about 200 spots or dots per array orlower.

In order to manufacture such arrays (100-200 spots/array) withproduction rates in the range of 1-1,000 million units per year, someembodiments contemplate utilization of in-line types of approaches usingweb or carrier formats for discrete substrates. Advantageously, thiswould allow the use of highly parallel dispensing strategies to allowlarge numbers of dispensers to operate in parallel to meet the requiredor desired production rates.

For array densities above 200 the same approach can be taken but thenumber of dispensers increases as does the cost. For example, if thecost per dispense channel is assumed to be about $10,000, then 3,000channels would cost $30,000,000. Hence, a different approach isdesirable to save on cost.

In some embodiments, for array densities above 200, a smaller number ofchannels could be used, such as 150 channels. This would involve 20aspirate/dispense (A/D) operations and hence reduce throughput by afactor of 20. It would also entail running the substrates 20 times underthe dispenser configuration which involves precise repositioning.

Thus, depending on the array density and the particular application andbudgetary constraints, certain embodiments of the invention involve ajudicious choice of the number of dispensers or dispense channels tooptimize the throughput while maintaining a balance between cost andtime. Hence, the particular dispense configuration can be customizedand/or optimized with efficacy, as needed or desired.

FIGS. 3-5 show exemplary embodiments of low density and medium densityarray format designs or concepts. These figures show respectivesubstrates or substrate assemblies 10 (10 a, 10 b, 10 c) comprisingrespective arrays or microarrays 12 (12 a, 12 b, 12 c).

FIG. 3 shows a 16 (4×4) spot array or microarray 12 a formatted in agenerally square (4×4) configuration with a plurality of spots 14 a on asubstrate surface or medium 16 a such as a glass slide or the like. Oneor more fiducial targets, indicia or marks 18 a can be provided tofacilitate proper alignment and/or orientation, such as duringprocessing, with efficacy, as needed or desired.

The dimensions shown in FIG. 3 are in millimeters (mm). In oneembodiment, the 16 spot density array or microarray 12 a has spots ordots located on (or spaced by) about 2 mm centers.

FIG. 4 shows a 40 (5×8) spot array or microarray 12 b formatted in agenerally rectangular (5×8) configuration with a plurality of spots 14 bon a substrate surface or medium 16 b such as a glass slide or the like.One or more fiducial targets, indicia or marks 18 b can be provided tofacilitate proper alignment and/or orientation, such as duringprocessing, with efficacy, as needed or desired.

The dimensions shown in FIG. 4 are in millimeters (mm). In oneembodiment, the 40 spot density array or microarray 12 b has spots ordots located on (or spaced by) about 2 mm centers.

FIG. 5 shows a 3,000 (30×100) spot array or microarray 12 c formatted ina generally rectangular (30×100) configuration with a plurality of spots14 c on a substrate surface or medium 16 c such as a glass slide or thelike. One or more fiducial targets, indicia or marks 18 c can beprovided to facilitate proper alignment and/or orientation, such asduring processing, with efficacy, as needed or desired.

The dimensions shown in FIG. 5 are in millimeters (mm). In oneembodiment, the 3,000 spot density array or microarray 12 c has spots ordots located on (or spaced by) about 2 mm centers.

The spot spacing for these exemplary array substrates 10 allows for thearrays 12 to be desirably made with drop sizes, which in someembodiments are, in the range from about 100 picoliters (pL) to about 50nanoliters (nL), including all values and sub-ranges therebetween. Incertain embodiments, the drop size or volume is in the range from about20 picoliters (pL) to about 1 microliter (μL), including all values andsub-ranges therebetween. Any of the dispensing techniques taught orsuggested herein, among others, may be used to dispense these dropsizes.

In some embodiments, a solenoid actuated dispensing technology is usedto form the arrays 12 by dispensing drop sizes in the nanoliter range,for example, the dispensing systems of FIGS. 2A-2F. In some embodiments,a piezo or piezoelectric dispensing technology is used to form thearrays 12 by dispensing drop sizes in the picoliter range, for example,the dispensing systems of FIGS. 1A-1C.

In certain embodiments, any of the dispensing technologies taught orsuggested herein, but not limited to, U.S. Pat. Nos. RE38,281 E,6,063,339, 6,599,479 B1, and US 2004/0219688 A1, the entirety of eachone of which is hereby incorporated by reference herein and comprises apart of the present patent specification/application, can beefficaciously used to form the array substrates 10 comprising arrays 12with dispensed drop sizes in the picoliter and/or nanoliter range, asneeded or desired.

The array substrates 10 a, 10 b, 10 c comprising respective arrays 12 a,12 b, 12 c, in some embodiments, share a common substrate size such thatthe substrates 10 a, 10 b, 10 c or respective substrate surfaces ormediums 16 a, 16 b, 16 c have substantially the same size. Thisdesirably facilitates in overall efficiency in substrate handling. Incertain embodiments, one or more of the substrates 10 (10 a, 10 b, 10 c)or substrate surfaces or mediums 16 (16 a, 16 b, 16 c) has a size whichis about the same as the size of a standard glass slide.

Hybridization

In general, the hybridization process comprises up to three steps, actsor elements. These, without limitation, are: (a) blocking for proteinarrays, (b) reaction of the sample/probe (e.g., solution, liquid orreagent such as chemical or biological) with the target (e.g., solution,liquid or reagent such as chemical or biological), and (c) washingexcess sample/probe from the substrate.

The reaction step or part typically requires good mixing, temperatureand time. The wash step typically needs to completely removesubstantially all excess unreacted probes. In conventional techniques,these process steps are typically done by flooding the entire arraysubstrate, which can undesirably add to the cost and time.

Certain embodiments of the invention by employing drop on drop modes ofoperation, as described further herein, are advantageously able toexecute these hybridization process steps by desirably using less probeand/or by achieving faster process times.

It should be noted that some types of arrays do not require blocking orwashing, such as for intercalating reactions, where the probe onlybecomes active when the assay reaction takes place.

Some Arraying and Hybridization Embodiments

Certain embodiments of the invention provide novel and improved systemsand methods for arraying. Some embodiments of the invention provide aweb based arraying format. Some other embodiments of the inventionprovide a sheet based arraying format.

Certain embodiments of the invention provide novel and improved systemsand methods for assaying and hybridization. Some embodiments use a dropon drop assaying or hybridization mode. In some embodiments, asubstantially inert substrate is utilized. In some other embodiments, aninteractive substrate is utilized.

Web Based Manufacturing Systems for Arraying

Some embodiments of the invention provide web based systems and methodsfor arraying. FIGS. 6-8 show an assay web substrate concept, design,structure or assembly 20 in accordance with certain embodiments.

The web substrate format or assembly 20, in some embodiments, isgenerally created based on the array formats of FIGS. 3-5 and isdesirably used for in line web based manufacturing. The web substrate 20comprises a plurality of substrate units or elements 22 with each havingan array or microarray 12 d formed thereon. The arrays 12 d eachcomprise a plurality of spots or dots 14 d arranged in a predeterminedmanner, such as but not limited to, for example, a rectangular or squarearray format.

The web substrate 20, in some embodiments, comprises a substrate surfaceor medium 16 d and a cover, carrier or shield 24 which are mechanicallyconnected to or in mechanical communication with one another. Thesubstrate surface or medium 16 d has the spaced arrays 16 d formedthereon.

In some embodiments, the substrate surface or medium 16 d comprises aflexible film or the like and is fabricated from, for example,polyester. The cover or carrier 24 comprises, for example, a plasticmaterial or the like, and desirably provides protection and/or at leastsome degree of controlled rigidity to the substrate surface or medium 16d to facilitate handling and processing of the web substrate structure20.

Each substrate unit 22, in some embodiments, comprises one or morefiducial targets, indicia or marks 18 d on the cover 24 to facilitateproper alignment and/or orientation, such as during processing, withefficacy, as needed or desired.

In certain embodiments, each substrate unit 22 comprises a bar code 26or the like to facilitate in identification, classification and/ordetection of the particular substrate unit and the array formed thereon.

Some exemplary dimensions are shown in millimeters (mm) in FIG. 8. Theembodiment of this figure also shows a 32 (8×4) array 12 d configuredwith spots or dots 14 d located on (or spaced by) about 2 mm centers.

FIGS. 9-12 show different views of an array dispensing machine or a webbased manufacturing system 30 to produce arrays or microarrays on acontinuous basis to form one or more web substrate structures such asthe web substrate 20 in accordance with certain embodiments of theinvention.

The web substrate manufacturing system 30, in some embodiments,comprises a staggered array of dispensers or dispense channels as shown.The web substrate manufacturing machine 30 includes, in someembodiments, web feeds for a plastic backing and substrate materialswhich are laminated followed by dispensing, drying and re-reeling.

The web substrate manufacturing system, apparatus or machine 30generally comprises a laminate module or section 32, a dispense moduleor section 40, a drying module or section 34, a capstan module orsection 36, and a take-up module or section 38 arranged in a successiveor consecutive manner with the laminate module 32 occupying the upstreammost position and the take-up module 38 occupying the downstream mostposition.

The laminate module 32, in some embodiments, comprises a backing reelapparatus 42 and a membrane reel apparatus 44 and a lamination orlaminating apparatus or system. The backing reel apparatus 42 provides abacking, cover or carrier (e.g., the plastic cover 24) and the membranereel apparatus 44 provides a membrane, film or substrate surface ormedium (e.g., the polyester film 16 d) which are laminated by thelamination apparatus of the module 32 to create one or more websubstrate devices onto which the appropriate reagent or liquid arraysare formed.

The dispense module 40 is used to dispense or deliver one or morereagents or liquids on to the web substrate device(s) to form arrays ormicroarrays thereon so as to form a web substrate structure (e.g., theweb substrate 20). In some embodiments, the dispense module 40 generallycomprises a dispense head 46 and an X-Y axis dispense head motionpositioner 48 to provide movement to the dispense head 46 and hencerelative motion with respect to the web substrate device(s) on which thearrays or microarrays are to be formed. The web substrate device(s) canalso be movable with respect to the dispense head 46 in someembodiments.

The dispense head 46 can comprise one or more dispensers or dispensechannels with efficacy, as needed or desired. In the illustratedembodiment, the dispense head 40 comprises a plurality of dispensers ordispense channels arranged in a generally staggered configuration.

The drying module 34 can comprise a suitable drying source such as anoven, fans or the like with efficacy, as needed or desired. The dryingmodule 34 is used to dry the dispensed reagent or liquid array spotsonto the web substrate (e.g., the substrate medium or surface 16 d).

The capstan module 36, in some embodiments, can comprise a rotatabledrum or shaft to move or drive a tape or the like, such as the preparedweb substrate structure(s) 20, at a predetermined (generally constant,but can be variable) speed towards and into the take-up module 38. Themanufactured web substrate structure(s) 20 are re-reeled into thetake-up module 38 from which they can then be retrieved, as and whenneeded, for assaying processes such as hybridization.

The movement of the web substrate from upstream to downstream may befurther facilitated in conjunction with various other devices, such as,but not limited to conveyor belts, pick-and-place robotic arms, and thelike. Desirably, a controller or control system is used to monitor andcontrol the operation of the web substrate manufacturing machine 30 withefficacy, as needed or desired.

FIG. 12 shows a staggered dispense location pattern, in accordance withsome embodiments, and an X-Y Cartesian axis or coordinate system. In oneembodiment, the staggered dispense locations have an about 9 mm pitch inthe X-direction and an about 2 mm pitch in the Y-direction. In modifiedembodiments, other dispense patterns, pitches and/or dimensional offsetsmay be efficaciously utilized, as needed or desired, depending at leastpartly on the particular application and/or process(es) involved.

In some embodiments, and as best seen in FIG. 12, the dispensing moduleor system 40 and/or the dispense head 46 comprises a plurality of bulkdispense channels or dispensers with the same number of channels asspots on the array. For a 5×8 array located on centers of 2 mm thedispense channels are grouped by sets of 5 with a 9 mm offset betweenchannels along the web axis and 2 mm centers perpendicular to the webaxis. There are 8 sets of the diagonal dispense array. Of course, as theskilled artisan will appreciate, the number, spacing and/or arrangementof the dispense channels can be efficaciously varied, as needed ordesired, depending at least partly on the particular application and/orprocess(es) involved.

Still referring in particular to FIG. 12, by using time delays betweenthe dispensers, each set of 5 channels can form, create or make a set of5 spots generally perpendicular to the web axis. A second set of delaysbetween the diagonal channel arrays places the sets of 5 spots at aspacing of 2 mm from the adjacent sets to finalize the creation of the5×8 array.

In one example, each array substrate length is about 60 mm, and byutilizing web speeds of 60 mm per second, the throughput is 1 part (orarray) per second which is equivalent to desirably about 6 millionarrays per year on a single shift basis. Using three shifts per day canthen advantageously achieve up to around 18 million arrays per year.Faster web speeds would yield even higher throughputs. This exemplifiedthe high throughput capabilities of certain web based embodiments of theinvention to achieve high speed array printing and manufacturing.

The reagent or liquid dispensing to form array(s) or microarray(s), suchas in accordance with web based embodiments, can be performed by any ofthe dispensing (and/or aspirating) systems taught or suggested herein,for example, those of FIGS. 1A-1C and 2A-2F.

In certain embodiments, the non-contact dispensing technologies of U.S.Pat. Nos. RE38,281 E, 6,063,339, and US 2004/0219688 A1, the entirety ofeach one of which is hereby incorporated by reference herein andcomprises a part of the present patent specification/application, areutilized for array printing, fabrication and/or manufacture. In one modeor embodiment of operation, continuous motion of the positivedisplacement syringe pump or device (or a direct current fluid source)with timing of valve opening, such as a solenoid dispenser or actuatorvalve, is employed for arraying. In another mode or embodiment ofoperation, controlled timing of valve, such as a solenoid dispenser oractuator valve, and syringe, such as a positive displacement syringepump or device (or a direct current fluid source), operations areefficaciously employed for array creation.

Any of the dispensing and/or array technologies (e.g., FIGS. 1A-1C andFIGS. 2A-2F) taught or suggested can utilize tandem systems orconfigurations. Other examples include those of U.S. Pat. Nos. RE38,281E, 6,063,339, 6,599,479 B1, and US 2004/0219688 A1, the entirety of eachone of which is hereby incorporated by reference herein and comprises apart of the present patent specification/application. Dispense heads orchannels can be efficaciously utilized to switch back and forth withrespect to the dispensers. For example, switching between dispense headsand/or channels may be utilized to allow for to allow for syringe refilland tip washing while a secondary system is dispensing. Advantageously,this can provide substantially uninterrupted operation and/or highthroughput processing.

In some embodiments, similar set ups can be used for high density arraycreation using the disposable/reusable piezoelectric pipette tiptechnology of Scienion, as taught or suggested herein. In certainembodiments, the Scienion sciFLEXARRAYER dispensers of FIGS. 1A and 1Bare utilized. In some embodiments, the non-contact piezo dispensingtechnology of U.S. Pat. No. 6,599,479 B1, the entirety of which ishereby incorporated by reference herein, is employed.

In general, for the piezoelectric dispenser technologies taught orsuggested herein the mode or embodiment of operation involves acontrolled timing of the piezoelectric actuation for creating the arrayor microarray. In some embodiments, for example, the case of the 3,000spot array (30×100) format shown in FIG. 5, the array configuration, incertain embodiments, can comprise 30 sets of 100 dispensers or dispensechannels in a 4.5 mm by 3 mm offset arrangement.

As the skilled artisan will appreciate, numerous non-contact dispensingtechnologies can be efficaciously utilized to achieve high throughputarray printing. In some modified embodiments, contact printing of arraysor microarrays can have efficacy in conjunction with other features andaspects of high speed array printing, hybridization, quantitativedevelopment and assaying, as taught or suggested herein.

In some embodiments, the liquid handling and dispensing technologiesdisclosed in U.S. Pat. Nos. 6,585,296 B1, 6,453,929 B1, 6,852,291 B1,6,569,687 B2, 6,627,157 B1, and US 2003/0167822 A1, US 2003/0170903 A1and US 2001/0053337 A1 are utilized, as applicable, in conjunction with,but not limited to non-contact dispensing and/or printing of arrays ormicroarrays. The entirety of each one of these U.S. patent documents ishereby incorporated by reference herein and comprises a part of thepresent patent specification/application.

FIGS. 13A and 13B show a dispensing instrument or system 210 asavailable from Innovadyne Technologies, Inc. which has some operationsin California, U.S.A. The dispensing system 210 can be efficaciouslyemployed in accordance with certain embodiments of the invention asdisclosed herein, including, but not limited to non-contact dispensingand/or printing of arrays or microarrays.

The dispensing instrument 210 utilizes two separate flow paths—a“syringe path” and a “pressure path”—to aspirate and dispense reagent.FIG. 13A illustrates reagent aspiration using the “syringe path” andFIG. 13B illustrates reagent dispensing using the “pressure path.”

Referring in particular to FIG. 13A, the syringe path is used toaspirate an air gap and reagent. The syringe path is the flow pathbetween the syringes and the tips, as shown in FIG. 13A. To aspirate anair gap, the tips are exposed to the atmosphere (not descended into thereagent tray), allowing air to flow into the tips. The valves areswitched into position, allowing flow from the tips to the syringes. Thesyringes are pulled down, creating a vacuum, and system fluid flows fromabove the reagent tray to the syringes. Air is aspirated through thetips and system fluid flows toward the syringes. Next, to aspiratereagent, the tips are descended into the reagent tray, then the syringesare pulled down further. Reagent flows from the reagent tray to thesyringes, separated from system fluid by the air gap.

Referring in particular to FIG. 13B, the pressure path, using a pressurereservoir filled with de-ionized system liquid held at system pressure,is used to dispense reagent. The pressure path is the flow path from thepressure reservoir, via the microsolenoid valves, to the tips, as shownin FIG. 13B. The pressure reservoir contains system liquid, maintainedby a digital pressure regulator (DPR) at a specified system pressure. Todispense reagent, the hybrid valve switches the flow from the syringepath to the pressure path, and then the microsolenoid valves are openedand closed the requisite number of times to permit the desired volume ofsystem liquid to flow from the pressure reservoir toward the tips. Notethat the reagent does not itself flow through the microsolenoid valves;system liquid does. The motion of the system liquid towards the tipsdisplaces the desired volume of reagent out through the tip, and reagentis dispensed into the plate.

In some embodiments, the liquid handling and dispensing technologiesdisclosed in U.S. Pat. Nos. 6,669,909 B2 and 6,713,021 B1, EuropeanPatent No. EP 1379332 B1, and PCT Patent Application Publication No. WO02/076615 A2 are utilized, as applicable, in conjunction with, but notlimited to non-contact dispensing and/or printing of arrays ormicroarrays. The entirety of each one of these patent documents ishereby incorporated by reference herein and comprises a part of thepresent patent specification/application.

FIG. 14 shows a dispensing system or apparatus 220 as available fromDeerac Fluidics which has some operations in Ireland and Massachusetts,U.S.A. The dispensing system 220 can be efficaciously employed inaccordance with certain embodiments of the invention disclosed herein,including, but not limited to non-contact dispensing and/or printing ofarrays or microarrays.

Referring in particular to FIG. 14, the system 220 utilizes a spot-on™technology to aspirate and dispense liquids or reagents. In someembodiments, the core of the spot-on™ technology is a pipetting tipwhich acts as a fast-actuating valve and which is connected to apressure or vacuum source. There is no system liquid within thepipettor—only air, and the sample liquid which is aspirated anddispensed through the tip. The tip preferably comprises a PEEK bodywhich contains a “boss” made of a magnet coated with a chemically inertmaterial. The boss when resting against the capillary creates a seal andcan be used as a valve. This valve is opened by raising the boss, whichcreates an opening to the capillary for the flow of the fluid. The bossis raised by the passage of a current through an electronic coil whichsurrounds the lower section of the tip body (as shown in FIG. 14). Theopening time for each aspirate and dispense is determined by thespot-on™ electronic controller from the supplied liquid properties, therequired or desired volume and other system parameters. Precise controlof the dispensation volume is further enabled by sensing the level ofmagnet actuation, using a sensing coil, and processing this informationinto a real time feedback. This feedback allows for the prospect ofmeasuring the viscosity and flow of the liquid to be dispensed, adding asignificant advantage to the spot-on™ technology.

Some unique and/or novel features, aspects and advantages in accordancewith certain embodiments of web based manufacturing systems for arrayinginclude, but are not limited to the following:

(1) Some embodiments advantageously provide continuous motion generationof arrays at high production speeds using non contact dispensing. Thesewould comprise continuous web or a web carrier with individual sheetsthat is indexed.

(2) Some embodiments desirably provide the ability to change arraypatterns using timing control and layout of the dispense channels withefficacy, as needed or desired.

(3) In certain embodiments, array patterns do not necessarily have to bemirrored in the dispenser configuration. One specific embodiment of theinvention is, that out of 3,000 dispensers, arrays manufactured from asubset of 384 dispensers might be the final product. Due to theversatile design of certain system embodiments, in principle every arraymanufactured can show a different composition of bioanalytes byaddressing a subset of dispensers to create subsets of arrays from thecomplete set of bioanalytes. This can desirably happen withoutdecreasing the speed of the conveyor belt. As a result, in someembodiments, and advantageously, identical and non identical arrayreplicates can be produced with an identical speed.

(4) Some embodiments desirably provide the ability to perform in lineinspection of array quality using wet/dry or other contrast methods withefficacy, as needed or desired.

(5) Some embodiments advantageously provide the ability to add otherreagent processes such as blocking and washing using emersion, spraycoating or drop on drop approaches with efficacy, as needed or desired.

(6) Some embodiments desirably provide the ability to combine othervalue added processing in line such as, but not limited to, lamination,drying, incubation, cutting, and punching, among others, with efficacy,as needed or desired.

Sheet Based Manufacturing Systems for Arraying

FIG. 15 shows an array dispensing machine or sheet based dispense arraymodule, apparatus or manufacturing system 50 in accordance with certainembodiments of the invention. In certain sheet based dispensingembodiments, such as that of FIG. 15, the dispensing is distributed overa number of dispense work stations 60 (60A, 60B, . . . , 60N) ascompared to embodiments of the continuous in line approach, such asthose of FIG. 9-12.

It is contemplated that the sheet based approach can be considered, atleast in some aspects, as a compromise manufacturing strategy relativeto the continuous web format. For example, the sheet based approach canbe suitable in applications where the substrate material may not lenditself to a web format due to thickness or mechanical rigidity or otherconsiderations.

The sheet based dispensing module 50, in some embodiments, generallycomprises a plurality of dispense work stations 60, one or morepositioning cameras 54 or the like, and a conveyor mechanism, system orapparatus 58. Each dispense work stations 60 comprises a dispense head66 with one or more dispense channels or dispensers.

Substrate assemblies or structures 70, in some embodiments, eachcomprise one or more dispense regions 16 e (or substrate units) on whichdispense patterns, arrays or microarrays 12 e are formed as thesubstrates 70 are transported via or on the conveyor mechanism 58. Inthese embodiments, the format of the arrays is in a sheet format or aX-Y carrier format which provides an X-Y presentation of arrays to thedispensing process.

In certain embodiments, an indexing in-line process can be establishedwhere the sheets or carriers can be moved through process steps such asdispensing, and drying, among others, similar to the continuous in-lineapproach embodiments. In some embodiments, the dispensing is done orperformed with the web or carrier in a stopped position and the motionis supplied by an overhead gantry motion system. In this case, thedispensing can be normal or parallel to the web/conveyor motion withefficacy, as needed or desired.

The reagent or liquid dispensing to form array(s) or microarray(s), suchas in accordance with sheet based embodiments, can be performed by anyof the dispensing (and/or aspirating) systems taught or suggestedherein. These include those described above in connection with web basedmanufacturing embodiments.

Some unique and/or novel features, aspects and advantages in accordancewith certain embodiments of sheet based manufacturing systems forarraying include, but are not limited to, those described above inconnection with web based manufacturing embodiments.

Some further unique and/or novel features, aspects and advantages inaccordance with certain embodiments sheet based manufacturing systemsfor arraying include, but are not limited to the following:

(1) Some embodiments efficaciously and desirably provide high throughputmanufacturing methods for substrate formats that do not lend themselvesto a continuous web format, as needed or desired.

(2) Certain embodiments advantageously provide the ability to do in-lineprocesses to maintain dispensing quality such as, but not limited to,periodic cleaning of dispense tips to ensure good quality dispensingwithout perturbing the quality and speed of the overall process. Forexample, the index time can be defined to allow ample time for tipcleaning.

Exemplary Formats for Continuous and Indexed Web Manufacturing Methods

The arraying systems and methods in accordance with certain embodimentsof the invention can efficaciously utilized to create, manufacture orproduce a wide variety of array or microarray substrate structures orassemblies, as needed or desired.

FIG. 16 shows a substantially passive or inert substrate structure 80 afabricated in accordance with certain arraying embodiments. An array 12ad comprising a predetermined or selected arrangement or configurationof dispensed liquid or reagent spots, dots or drops 14 ad is formed on amembrane, substrate surface or medium 16 ad. The substrate surface ormedium 16 ad can serve as a carrier or an independent carrier 24 ad maybe employed with efficacy, as needed or desired.

FIG. 17 shows a substantially active or interactive substrate structure80 b fabricated in accordance with certain arraying embodiments. Anarray 12 bd comprising a predetermined or selected arrangement orconfiguration of dispensed liquid or reagent spots, dots or drops 14 bdis formed intermediate a membrane, substrate surface or medium 16 bd anda carrier 24 bd. An absorbent material 82 is generally provided betweenthe membrane, substrate surface or medium 16 bd and the carrier 24 bdand adhesive junctions 84 or the like are utilized to laminate, attachor connect the membrane and carrier.

Referring in particular to the inert substrate embodiment of FIG. 16,test reagents or liquids (e.g., in the form of droplets 14 ad) are putdown or dispensed onto the substrate surface or membrane 16 ad whichdoes not chemically interact with the reagent or liquid and hence thedrops 14 ad hydrodynamically sit or reside on the substrate surface ormedium 16 ad. In this case the type of assay that can be used here maybe limited since under hybridization conditions the substrate cannot bewashed as the material will be removed. However, advantageously, incertain embodiments, by using an intercalating dye type based method fordetection of DNA binding events where only positive probe and targetreactions turn on the probe, the wash step is not needed. Also, againadvantageously, blocking steps are not required since the substrate isinert. One example of such an assay would be a Single-NucleotidePolymorphism (SNP) assay on a polyester film in either a web or sheetformat.

Referring in particular to the interactive substrate embodiment of FIG.17, the targets or drops 14 bd actually bind to the substrate. In thiscase, both blocking and washing steps are typically performed tocomplete the assay for reading. The active substrate 80 b represents oneexample of such an assay format suitable for the proposed in line forindexing approach described above which is an adaptation of a flowthrough commonly used for protein assays. In one embodiment, thesubstrate device 80 b generally comprises a plastic backing 24 bd, anitrocellulose membrane 16 bd and an absorbent spacer 82 that islaminated between the membrane substrate 16 bd and the plastic carrier24 bd. In this case, the membrane 16 bd comprises the active substratesurface.

FIG. 18 shows a Polymerase Chain Reaction (PCR) adaptable substratestructure or assembly 80 c in accordance with certain embodiments. Thesubstrate device 80 c employs an array or microarray configuration suchas a sheet with welds 16 cd or a microtiter format. The substrate device80 c can utilize a carrier or backing 24 cd with efficacy, as needed ordesired. A plurality of such devices 80 c may be conveyed on a suitabletransportation device. The PCR assay employs amplification and hascertain special processing steps in accordance with embodiments of theinvention. The substrate device 80 c can be customized, for example,based on the number, spacing and/or arrangement of array sites, dots ordrops with efficacy, as needed or desired.

In certain embodiments, and as discussed further below, assaying basedon a PCR format such as a TaqMan® assay is performed. An array isdispensed into a PCR plate such as the substrate plate 80 c of FIG. 18.In this case, the array comprises a set of oligonuclides including aTaqMan® probe. For certain embodiments of this PCR assay, the reactionis performed under an oil layer and a master mix (TaqMan® master mix)and sample are dispensed through the oil. As discussed below, a thermalcycler is utilized followed by reading.

Drop on Drop Methods and Hybridization Equipment Systems

FIG. 19 shows embodiments in accordance with precision drop on drop (orspot) dispensing for hybridization and/or assaying processes whichadvantageously provide for, among other desirable features, highthroughput and judicious utilization of valuable liquids or reagents. Inparticular, the figure schematically illustrates the dispensing of aliquid or reagent drop or droplet 14′ onto a liquid or reagent drop,spot or dot 14 such as one formed as part of an array on a substrate. Insome embodiments, the drop 14′ is dispensed at a certain predeterminedor selected velocity (V) or momentum to advantageously facilitatedesirable kinetic mixing and/or reaction between the drop 14′ and thearrayed spot 14.

Inert Substrate Related Embodiments:

FIGS. 20-23 show various views of some embodiments of a bench tophybridization (and/or assaying) system 90 particularly suited to thehybridization of a single array. In this case, only the probe or sample(e.g., reagent(s)) typically needs to be added to the substrate coupledwith heating for the hybridization process. After this the array isready for reading.

The hybridization machine 90 can utilize any of the dispensing (and/oraspirating) technologies (e.g. those of FIGS. 2A-2F) as taught orsuggested herein with efficacy, as needed or desired. Certainembodiments of the machine 90 are configured with any of the solenoidactuated or piezoelectric dispensing technologies of U.S. Pat. Nos.RE38,281 E, 6,063,339, 6,599,479 B1, and US 2004/0219688 A1 the entiretyof each one of which is hereby incorporated by reference herein andcomprises a part of the present patent specification/application.

In some embodiments of these cases, the input to the machine 90 would bethe sample (e.g., liquid reagent(s)) in the format of a microtiter plateand a master mix as a bulk reagent that is mixed with the sample. Thework station comprises two dispense channels: a) one is to add themaster mix to the sample with mixing and b) one is to aspirate themixture followed by dispensing onto each individual spot in the arrays.After drying the arrays are ready for reader analysis. Typically, thissystem would be targeted at low volume use for point of testing type ofapplications. The hybridized array would then go to a read station.

Referring in particular to FIG. 22, in certain embodiments, the systemor machine 90 generally comprises, among other things, a dispense head91, one or more syringe pumps 92, an array nest 93, a source plate nest94, and a wash station 95.

Referring in particular to FIG. 23, an enlarged view of the dispensehead 91 shown along with, among other things, an array nest (40×120shown) 93′ and a differential Z-axis actuator 96. The dispense head 91,in certain embodiments, comprises one or more bulk dispense channels 97and one or more aspirate and dispense channels 98.

FIGS. 20-23 generally show an AD1500 Research System as available fromBioDot, Inc. of Irvine, Calif., U.S.A. Any of the liquid handling,dispensing, aspirating, arraying, hybridization embodiments, amongothers, disclosed herein can efficaciously utilize BioDot's AD3050Research System, AD3200 Development System, AD3400 Development System,and AD6000 Production System. For example, in some arrangements, theAD6000 machine can comprise up to 96 dispense channels. In somearrangements, the AD6000 machine can fill 1536 well plate with 500nL/well in about 20 seconds.

FIGS. 24-26 show various views of some embodiments of a sample storage,dispense master mix and magazine loader system 100 and a hybridizationand reading system 110 particularly suited for high volume assay arrayapplications. FIGS. 27-31 show various views of certain otherembodiments of a high volume array printing, hybridization and readingsystem or assay array machine 120.

Referring in particular to FIG. 24, the system 100 in certainembodiments generally comprises, among other things, a sample platestorage system 230, a master mix dispense head 232, a magazine loader234, and sample micro-plates 236.

Referring in particular to FIG. 25, the system 110 in certainembodiments generally comprises, among other things, a supply module240, a magazine storage module or device 242, a reader module 244, and atake-up module 246.

Referring in particular to FIG. 26, this drawing in certain embodimentsgenerally shows, among other things, a camera positioner 250, conveyedmaterial 252, a 8-channel dispense head 254, an arrayed pattern 256, anda micro-well plate 258.

Referring in particular to FIG. 27, the machine 120 in certainembodiments generally comprises, among other things, a payout module260, a dispense module 262, a vision module 264, an incubation module266, a reader module 268, and a take-up module 270.

Referring in particular to FIG. 31, this drawing in certain embodimentsgenerally shows, among other things, conveyed material 272, a 8-channeldispense head 274, an arrayed pattern 276, and a MTP source 278.

The embodiments of FIGS. 24-31 are particularly suited whereinhybridization and reading is done in a central laboratory and thetesting is at a much higher volume (compared to the embodiments of FIGS.20-23), for example, into the tens of millions or more annually. Certainembodiments of FIGS. 24-31 advantageously integrate both thehybridization and reading process together using a web based system forhandling the arrays. In addition to the web handling module withdispensing, heating and reading the system comprise a sample store wherethe samples that come into the testing laboratory are stored. Thesamples could represent patient samples for medical tests, plant samplesfor agriculture crop or animal testing, or a wide range of other typesof testing applications that are tested in a central laboratoryenvironment.

Embodiments of the example machines 100, 110, 120 comprise one or morework stations or modules which are described further below. For thisexample, it is assumed that the test volume is about 10-100 microliters(μL) per sample using 96 well sample formats working 3 shifts per day totest 1.4 million samples per year or 8,000 samples per day or about80-96 plates per day. These numbers are based on 4000 hours per year ofavailable analysis time. The storage capacity of plates is assumed to bein the range of 5-10,000 plates. The store system can supply plates to anumber of Hybridization Systems.

Some features of embodiments of the sample store and hybridizationsystems are described below with particular reference to the embodimentsof FIGS. 24-31 and machines 100, 110, 120:

SAMPLE STORE MODULE: This system stores the sample plates before andafter testing and has a capacity for storing up to 20,000 plates. Otheroperations within this module will be to thaw the plates, fill withmaster mix and then place the plates into transfer magazines.

Plate Handling Station: This station includes a barcode reading systemand pick and place devices, such as robotic arms or the like, which canplace or retrieve plates from the store racks.

Plate Storage Station: This station is a temperature controlled storagesystem with storage racks and a rack handling system. Each rack has aunique position within the storage system and each plate had a uniqueposition on a given rack.

Dispense Master Mix Station: At this station the plate is thawed andthen master mix is dispensed into the plates.

Magazine Load/Unload Station: This station loads the plates into atransfer magazine which then are located on the dispenser station on aHybridization/Reader Module.

HYBRIDIZATION/READER MODULE: This module dispenses the sample to thetest array followed by incubation and reading.

Web Feed Station: This station comprises a web feed module for the arrayweb that has been printed on the master manufacturing machine. In thiscase the web is fed using an index mode to position a set of arrays inthe Dispense Station. In this example we assume the positioning of 8 ofthe low density or 4 of the high density arrays per index.

Dispense Sample/Master Mix Station: This station comprises an overheadgantry module with a vision camera; two 8 channel dispenser and tip washstations working in tandem to provide continuous indexing of the web.Each dispense head alternately aspirates 8 reagents and dispenses either4 high density or 8 low density samples on arrays. After dispensing thedispense channels are cleaned for the next index cycle. Each sample isassigned the bar code of the individual arrays where the dispensingoccurs.

Incubation Station: This station comprises an incubation tunnel wherethe arrays are heated to a determined temperature with a controlledlevel of humidity.

Read Station: This station comprises a reader head mounted on anoverhead gantry. At each index step either 4 or 8 arrays are read by thecamera and the data transferred to the system data base.

Web Take-up Station: This station comprises a take-up real forcollection of the web.

Some unique and/or novel features, aspects and advantages in accordancewith certain embodiments of sample storing, arraying, hybridization andreading systems include, but are not limited to the following:

(1) Some embodiments provide an array format on a web with unique barcodes for each test position.

(2) In some embodiments, alignment features are provided on each arrayfor positioning using vision or other methods for application ofreagents and reading.

(3) Certain embodiments provide Barcode, punch card, and/or RadioFrequency Identification Device (RFID) identifiers on samples plateswith a data base that identifies individual well samples.

(4) Some embodiments comprise a sample storage system that can input newsamples sent to the laboratory into the data base and can output thesesamples to the web hybridization/reader system. This would include themanual or automatic transfer to microtiter plate or other samplecontainers between the store and hybridization/reader system.

(5) In some embodiments, a data base tracking system is utilized thatprovides for collection, reading and sending of data for each samplethat includes the analysis data and interpretation.

(6) Some embodiments provide a dispensing system that includes theability to process multiple tests to provide for the ability to achievehigh throughput processing.

(7) In some embodiments, an incubation system provides for thehybridization process to take place after application of the sample withmaster mix.

Interactive Substrate Related Embodiments:

An example of this type of array format is shown as the interactivesubstrate 80 d in FIG. 17 for a flow through type of substrate. Otherexamples can include a membrane attached directly to the substrate orother surfaces that have been directly functionalized to bind with thetarget species. For these types of devices certain changes and/oradditions are needed or desired in conjunction with the embodiments ofthe Manufacturing and the Hybridization/Reader machines described above.

FIGS. 32-34 show different views of certain embodiments of a web basedinteractive array assembly system 130 comprising a blocking module 132.The array assay blocking wash flow through device manufacturing machine130 is generally similar to the embodiments of the array manufacturingmachine 30 of FIGS. 9-12 except that it has an added blocking/dryingstation 132.

Referring in particular to FIG. 32, the system 130 in certainembodiments generally comprises, among other things, a backing reel 280,a membrane reel 282, a Y-X axis head motion positioner 284, a laminatemodule 286, a dispense module 288, the blocker spray or dip module 132,a drying module 290, a capstan module 292, and a take-up module 294.

The blocking/drying stations 132 can efficaciously comprise a liquiddip, aerosol spray of dispensing of a blocking solution directly ontothe spots. As shown, for example in FIG. 32, these stations 132 arelocated directly after the dispense station or module.

In connection with embodiments of the Hybridization/Reader Machine,washing/drying stations are desirably added after the incubation stationand before the reader station.

PCR Substrate Related Embodiments:

In some embodiments, a PCR assay is executed with a PCR plate such asthe PCR plate or substrate 80 c shown in FIG. 18. As set ofoligonucleotides are added or dispensed at the dispensing station of anassay array assembly or manufacturing machine. In one embodiment, thesecomprise two primers and a TaqMan® probe.

A TaqMan® assaying system as available from Applied Biosystems of FosterCity, Calif., U.S.A. has efficacy with certain particular features ofPCR assaying in accordance with some embodiments. Applied BiosystemsTaqMan® gene expression assays solutions are discussed in further detailbelow.

In certain embodiments, the assay machine is used to dispense a cover orhost fluid, such as oil or other suitable substantially immiscibleand/or inert liquid, onto or into the array formed on the PCR plate 80 cin the form of an oil layer or layers. Typically, an oil layer wouldcover each of the individual array sites, spots, drops or dots A mastermix (in one embodiment, a TaqMan® master mix) and a selected sample(s)are then dispensed through the oil layer using non-contact dispensing sothat the reaction(s) take place under the oil layer.

European Patent No. EP 1 485 204 B1, the entirety of each one of whichis hereby incorporated by reference herein, discloses systems andmethods for dispersing or dispensing liquids or reagents below a fluidsurface using non-contact dispensing which can be efficaciously utilizedin accordance with certain embodiments of the invention. This patentdocument comprise a part of the present patentspecification/application, and a copy of it is also attached herewith aspart of the specification.

In these PCR assaying embodiments, the incubation chamber, station,module or system is replaced by a thermal cycling or cycler station,module, system or process. The PCR substrate(s) 80 c are then read atthe read, reading or reader station, module or system. Thissubstantially completes the PCR assaying process.

Applied Biosystems TaqMan® Gene Expression Assays

Applied Biosystems offers one of the largest family of products to meetyour quantitative gene expression needs: from off-the-shelfgene-specific probe and primer sets to Custom TaqMan® probes and primersmanufactured to your desired sequences, and everything in between. Allproducts use TaqMan® probe-based chemistry and are designed for use onthe suite of Applied Biosystems Real-Time PCR Systems—together the goldstandard in quantitative gene expression offering the greatestsensitivity, specificity, reproducibility, and the broadest dynamicrange.

TaqMan® Gene Expression Assays

TaqMan®Gene Expression Assays

Gene-specific TaqMan® probe and primer Convenient single-tube formatsets for quantitative gene expression studies Human, mouse, rat,Arabidopsis, Drosophila, Universal cycling conditions C. elegans, Rhesusmacaque, and canine species available

TaqMan® Gene Expression Assays are a comprehensive collection of over700,000 pre-designed probe and primer sets that enable researchers toquickly and easily perform quantitative gene expression studies on human310, mouse 320, rat 330, Arabidopsis 340, Drosophila 350, C. elegans360, Rhesus macaque 370, or canine 380 genes (see FIG. 35A). Each geneexpression assay consists of a FAM™ dye-labeled TaqMan® MGB probe andtwo PCR primers formulated into a single tube. Every assay is optimizedto run under universal thermal cycling conditions with a final reactionconcentration of 250 nM for the probe and 900 nM for each primer. Thisstreamlined approach and comprehensive assay selection enables aconvenient, standardized process for quantitative gene expression.

Human Assays

Over 200,000 gene expression assays are available for all known humangenes. These include genes in the public domain with associated RefSeqtranscripts (NCBI Reference Sequence project database:http://www.ncbi.nlm.nih.gov/RefSeq), the mammalian gene collection(MGC), and GenBank® database. A minimum of one assay (probe and primerset) per RefSeq transcript is available as an inventoried, off-the-shelfproduct currently numbering >24,000 assays. The complete collectionincludes assays for nearly every exon junction in all known human genes,both in the public domain and the Celera database, covering every probeon the Applied Biosystems Expression Array System.

Mouse and Rat Assays

Over 300,000 mouse and rat assays have been designed for all knowngenes. As with our human assays, at least one assay per RefSeqtranscript has been manufactured and is available from our inventory.High quality assay designs for all other genes are also available on amade-to-order basis, as Custom TaqMan® Gene Expression Assays.

Strain-Neutral Mouse and Rat Assays

The assay design process yields strain-neutral mouse and rat geneexpression assays. Polymorphisms are the cause of most sequencevariability between strains. By avoiding areas in the gene transcriptsof known polymorphisms, we design only strain-neutral gene expressionassays.

TaqMan® Gene Copy Number Assays

TaqMan Gene Copy Number Assays are now available to detect gene copynumber. Copy number is an important polymorphism in the human genomeassociated with genetic diseases such as cancer, immune diseases, andneurological disorders. Drug metabolizing enzymes were selected as thefirst set of TaqMan Gene Copy Number Assays due to their significance inhuman physiology and disease. Gene Copy Assays were designed to detectCYP2D6, CYP2A6, CYP2E1, GSTT1, and GSTM1.

TaqMan Gene Expression Assays for Mitochondrial DNA Transcripts

TaqMan® Assays are also available for 19 mitochondrial (mt) DNA encodedtranscripts, including 13 mt mRNAs, two mt mRNAs and one mt D-Loop.Three additional assays targeting the mt inter-tRNA region are availableas Custom TaqMan Gene Expression Assays. Our TaqMan Assays targetingmtDNA transcripts are ideal for sensitive, specific, and accuratequantification of mtDNA transcription.

Like all TaqMan Gene Expression Assays, measurements are made inreal-time, use universal cycling conditions and TaqMan® Universal PCRMaster Mix.

Comprehensive Coverage and Selection

Not only have we designed an assay for every gene, but also for multiplelocations across each gene transcript. More than 700,000 high-qualityassay designs are available for human, mouse, rat, Arabidopsis,Drosophila, C. elegans, and canine genes on a made-to-order basis. Thisvast selection allows researchers to select the specific location on agiven transcript they wish to detect. For instance, microarrayresearchers that may prefer a 3′ bias in their TaqMan® probe and primersets will be able to select from robust, pre-designed TaqMan® GeneExpression Assays. Additionally, researchers performing RNA studies canchoose multiple assays per gene to validate their knockdown results.

State-of-the-Art Assay Design Bioinformatics

All assays are designed using Applied Biosystems sophisticatedbioinformatics pipeline, customized for either the human, mouse, or ratgenome. This pipeline consists of three main steps.

Step One—

Both public and Celera sequence data are used to identify the optimalprobe and primer locations. This process comprises: mapping transcriptsto the genome to identify exon boundaries; masking sequencediscrepancies between public and Celera data; masking sequence repeats;and masking known SNPs from both public and Celera databases.

Step Two—

Proprietary software algorithms generate probe and primer design for thelocations identified above. These algorithms include optimal designparameters, such as % GC content, Tm, amplicon length, and low secondarystructure to ensure high amplification efficiency. Where possible,designs span an exon-exon junction, eliminating the possibility ofdetecting genomic DNA.

Step Three—

In silico QC ensures each assay is specific to the gene for which it wasdesigned (i.e., the assay will not detect sequences from other genes, orpseudo-genes). Each assay design is processed through a quality scoringsystem and one high scoring, gene-specific assay design is sent to ourstate-of-the-art manufacturing facility. All designs meeting our scoringcriteria are also displayed in our online catalog and are available on amade-to-order basis. Our graphical map viewer shows each assay'slocation on the gene to help determine which assay is most appropriate.

Choice of Delivery Formats

Applied Biosystems delivers the assays in either a tube-format orTaqMan® Low Density Array-format (using inventoried assays only). TheTaqMan® Low Density Array is a 384-well micro fluidic card thatstreamlines reaction set-up time, eliminates the need forliquid-handling robotics, and provides standardization across multipleusers and/or multiple labs. This format is ideal for analyzing manysamples across fixed number of targets, such as for biomarker screening.TaqMan® Arrays arrive ready to use, with your selected TaqMan® GeneExpression Assays pre-loaded into each of the 384 reaction wells. Simplyadd 100 mL sample mix (sample cDNA and TaqMan Universal PCR Master Mix)to each of the eight sample ports and run on an Applied Biosystems7900HT Fast Real-Time PCR System. For more information, see the “TaqManLow Density Array” section on page 9.

Custom TaqMan® Gene Expression Assays

Custom TaqMan® Gene Expression Assays are delivered ready-to-use, alongwith the probe and primer sequences you designed. Features include: anyspecies or organism; target sequence of your choice; convenientsingle-tube format; and available in small, medium, and large scales.

Custom TaqMan® Gene Expression Assays are available for any species, anysplice variant or any novel gene. Simply download our free File BuilderSoftware to format and submit your target sequence, File BuilderSoftware can be downloaded at www.appliedbiosystems.com/filebuilder. Thesoftware easily guides you through the ordering process of selecting theassay size, formatting your target sequence to identify the location ofthe probe, and submitting your order via e-mail.

File submissions are done in a secure format. Your target sequences andthe associated assays that are designed are kept confidential. WithCustom TaqMan Gene Expression Assays, you benefit from AppliedBiosystems proprietary software algorithms for probe and primer design,which enable you to obtain optimal assays for each target sequence.Assays are delivered in a single-tube, ready-to-use format, along withthe probe and primer sequences designed from your submitted sequence.

Automation-Compatible to Accelerate High-Throughput Applications

Both TaqMan® Gene Expression Assays and Custom TaqMan® Gene ExpressionAssays come pre-formulated in a single, 2D-barcoded tube with aneasy-to-read label. The single-tube format requires fewer set-up andpipetting steps to assemble reactions, assisting you to easily scaleyour throughput. Assay tubes are shipped in a 1D-barcoded 96-positionrack designed to accommodate standard liquid-handling robotics and fitseamlessly into automated, high-throughput laboratory processes. Eachorder of assays also includes a compact disc with an assay informationfile that includes the assay ID numbers, detector names, reporter dye,and quencher information for easy uploading into a LIMS or sequencedetection system software.

A Simple Standardized Solution for Quantitative Gene Expression

TaqMan Gene Expression Assays and Custom TaqMan Gene Expression Assaysare built on our 5′ nuclease chemistry and consist of a FAM™ dye-labeledTaqMan® MGB probe (250 nM, final concentration), and two unlabeled PCRprimers (900 nM each, final concentration). All components are QC testedand formulated into a single 20× mix. Designed to run under universalconditions for two-step RT-PCR, TaqMan Gene Expression Assays are simpleto use. Just add TaqMan® Universal PCR Master Mix (with or withoutAmpErase® UNG) and your cDNA sample to generate sensitive, reproducible,and truly quantitative gene expression data on any Applied BiosystemsReal-Time PCR System.

Compared to do-it-yourself methods, TaqMan Gene Expression Assays andCustom TaqMan Gene Expression Assays eliminate weeks or even months ofprobe and primer design, formulation, and testing.

TaqMan® Endogenous Controls

Features include: optimized, pre-formulated, ready-to-use controlassays; cost-effective gene expression quantitation in human, mouse,rat, and eukaryotes (18S rRNA); Choice of FAM™ or VIC® dye labels.

Applied Biosystems TaqMan® Endogenous Controls are a collection ofpre-designed probe and primer sets that can be used to normalize theamount of sample RNA or DNA added to a reaction. For the quantitation ofgene expression, deciding upon a specific control can be difficult, evenwhen detailed information about the biological system is available. Thiscan result in trial and error to identify an appropriate control,leading to project delays and increased costs. Applied Biosystems offersendogenous controls for the most commonly used control genes in human,mouse, rat and any eukaryotic (18S rRNA) species. The assays aredesigned to help researchers quickly and easily identify and run thebest possible endogenous control for their gene expression study.

A Simple Standardized Solution for Quantitative Gene Expression

Each endogenous control is built on our 5′ nuclease chemistry and isoffered in a choice of two different reporter dyes and two quenchers: aFAM™ dye-labeled TaqMan® MGB probe (250 nM, final concentration) and twounlabeled PCR primers (900 nM each); a VIC® dye-labeled TaqMan® MGBprobe (250 nM, final concentration) and two unlabeled PCR primers (150nM each—primer limited); and a VIC dye-labeled TAMRA™ dye-labeled probe(250 nM, final concentration) and two unlabeled PCR primers (150 nMeach—primer limited).

All components are QC tested, formulated into a single 20× mix, andfunctionally tested. Designed to run under universal conditions fortwo-step RT-PCR, our TaqMan Endogenous Controls are simple to use. Justadd TaqMan® Universal PCR Master Mix (with or without AmpErase® UNG) andyour cDNA sample to generate sensitive, reproducible, and trulyquantitative gene expression data on ABI Prism® 7000 and 7700 SequenceDetection Systems, Applied Biosystems 7300 and 7500 Real-Time PCRSystems, and Applied Biosystems 7500 and 7900HT Fast Real-Time PCRSystems. Compared to do-it-yourself methods, our TaqMan EndogenousControls deliver a complete quantitation solution and eliminate weeks oreven months of assay design, formulation, and testing.

Choosing the Right Endogenous Control

Endogenous controls can normalize the expression levels of target genesby correcting differences in the amount of cDNA that is loaded into PCRreaction wells. For best results, verify that the endogenous control isconsistently expressed in the sample set to be tested. Endogenouscontrol expression must be uniform across all samples in the study. Formultiplexing, ensure that the gene expression level of the endogenouscontrol is greater than that of the target.

Multiplex Vs. Singleplex PCR

All TaqMan® Endogenous Controls that contain probes labeled with the VICreporter dye are primer limited. This allows multiplexing of TaqManEndogenous Controls with target gene expression assays, provided thatthe control gene is more abundantly expressed than the target gene. AllTaqMan Endogenous Controls the contain probes labeled with the FAMreporter dye are not primer limited and are not intended formultiplexing.

Complementary Products

TaqMan® Endogenous Controls are intended to be used with: TaqMan® GeneExpression Assays; custom TaqMan® Gene Expression Assays; TaqMan®Pre-Developed Assay Reagents (PDARs); and Custom TaqMan® Probes andPrimers.

TaqMan ® Endogenous Controls Eukaryotic 18S rRNA Human ACTB (beta actin)Human B2M (beta-2-microglobulin) Human GAPD (GAPDH) Human GUSB (betaglucuronioase) Human HPHT1 Human PGK1 (phosphoglyceratekinase 1) HumanPPIA (cydophilin A) Human RPLO (large ribosomal protein) Human TBP(TATA-box binoing protein) Human TFRC (CD71) (transferring receptor)Mouse GAPD (GAPDH) Mouse ACTB (beta actin) Rat GAPD (GAPDH) Rat ACTB(beta actin)

TaqMan® Low Density Array

Features include: validate microarray hits quickly and economically;standardize screening of gene panels across many samples andlaboratories; create the perfect card by designing a custom array thatmeets your specific need; and load 384 wells in less than five minuteswithout robotics or multi-channel pipettors.

The TaqMan® Low Density Array is a 384-well micro fluidic card thatenables you to perform 384 simultaneous real-time PCR reactions withoutthe need for liquid-handling robots or multi-channel pipettors to loadsamples. This low- to medium-throughput array enables 1 to 8 samples tobe run in parallel against 12 to 384 TaqMan® Gene Expression Assaytargets that are pre-loaded into each of the wells in the array. TheTaqMan Low Density Array is completely customizable—choose from over47,000 inventoried TaqMan Gene Expression Assays designed for human,mouse, and rat genes to have loaded into a TaqMan® Array. The TaqManArray is designed for use on the flexible Applied Biosystems 7900HT FastReel-Time PCR System with a 7900HT TaqMan® Array Upgrade.

The Ultimate Microarray Validation Tool

TaqMan Arrays are exactly the right tool for validating the tens orhundreds of hits that come from microarrays because they can becustomized to include up to 384 of those hits in one easy-to-use card.Using individual assays, or even SYBR®-based assays, to look at 12, 48,or 96 targets can quickly become unmanageable and expensive. TaqMan LowDensity Arrays enable researchers to accomplish the validation necessaryto arrive at the right answer easily and affordably.

Ideal Screening Technology

TaqMan Low Density Arrays are ideal for screening biomarkers andtoxicology panels, and for analyzing pathways, target classes, andcomplete disease sets. Because TaqMan Arrays don't requireliquid-handling robotics for loading, you get standardized results withlow variability across many users and laboratories. Plus, TaqMan GeneExpression Assays—the benchmark of specificity and sensitivity inreal-time PCR—are pre-loaded into the TaqMan Array, ensuring reliableperformance and results you can trust.

Create the Perfect Card

You select TaqMan Gene Expression Assays and the optimal TaqMan Arrayformat for your experiment, and we deliver TaqMan Low Density Arrayspre-loaded with your selected assays in each reaction well. Choose 12 to384 target assays from our collection of inventoried TaqMan GeneExpression Assays covering human, mouse, and rat genes. Ordering is easywith the new online TaqMan Low Density Array configuration tool to helpyou search and select genes and assays. Custom TaqMan Arrays areavailable in nine different formats, covering 12, 16, 24, 32, 48, 64, 96(2 choices), and 384 assays per Low Density Array.

Designing a TaqMan Low Density

Customizing a TaqMan Low Density Array can be done through the AppliedBiosystems Web site. Choose your ideal format and TaqMan Gene ExpressionAssays, select a quantity, and place your order—it's as easy as 1, 2, 3.Or, download our list of customizable gene panels to define a particulartarget class or pathway using public databases and published articles.The gene lists include a TaqMan Gene Expression Assay to represent eachgene in the list that can be used to configure a custom TaqMan Array.

Taqman Low Density Array Format Specifications

TaqMan® Low Density Array (384-well micro fluidic card):

# of Samples per Card 1 Repli- 2 Repli- 3 4 Repli- Description # ofAssays cate cates Replicates cates Format 12 11 + 1 Control 8 Format 1615 + 1 control 8 Format 24 23 + 1 control 8 4 Format 32 31 + 1 control 4Format 48 47 + 1 control 4 2 Format 64 63 + 1 control 2 Format 96a 95 +1 control 2 1 Format 96b 95 + 1 control 2 1 Format 384 380 + 1 control 1

TaqMan® Low Density Array Gene Signature Panels

Features include: pre-formatted and inventoried for quick delivery;economical two- or four-card packages simplifies your workflow; TaqManGene Expression Assay performance without expensive robotics; andconsistent, reliable data across samples, studios, and labs.

TaqMan® Gene Signature Panels are pre-designed, focused gene panels formany important target classes and pathways. Gene sets in each panel havebeen culled from pathway analysis tools, published review papers, andcollaborator and customer input. Select from a variety of TaqMan GeneSignature Panels based on your research needs covering such areas asGPCRs, immune response, or protein kinases. Endogenous Control Panelsare also available to assess which housekeeping genes are best for yourspecific study. TaqMan Gene Signature Panels provide a faster deliverytimes than our custom TaqMan Arrays because they are alreadyinventoried. TaqMan Gene Signature Panels are packaged in two or fourcards per pack, making them more cost effective.

TaqMan® Low Density Array

TaqMan® Arrays can be ordered in any of the following format options:Format 12 (P/N 4342247)—11 unique assays+1 mandatory control, and 8unique samples; Format 16 (P/N 4346798)—15 unique assays+1 mandatorycontrol, and 8 unique samples; Format 24 (P/N 4342249)—23 uniqueassays+1 mandatory control, and 8 unique samples; Format 32 (P/N4346799)—31 unique assays+1 mandatory control, and 4 unique samples;Format 48 (P/N 4342241)—47 unique assays+1 mandatory control, and 8unique samples; Format 64 (P/N 4346800)—63 unique assays+1 mandatorycontrol, and 2 unique samples; Format 96a (P/N 4342259)—95 uniqueassays+1 mandatory control, and 4 unique samples; Format 96b (P/N4342261)—95 unique assays+1 mandatory control, and 2 unique samples; andFormat 384 (P/N 4342265)—380 unique assays+4 mandatory controls, and 1unique sample.

Custom TaqMan® Probes and Primers

Features include: choice of dye labels, quenchers, and synthesis scales;available for any species or organism; and for use in quantitative geneexpression, SNP genotyping, other allelic discrimination applications,and pathogen detection

When you know the exact sequences you need for your TaqMan® probes andprimers, Applied Biosystems can synthesize them for you. As the marketleader in real-time PCR, our high-quality custom products can be used inall of your real-time and end-point PCR applications. These productsoffer you the ideal in flexibility, whether you prefer to optimize yourown reaction formulation, or if you simply require large quantities

Our Custom TaqMan® Probes and Primers are manufactured at three sitesaround the world—the United States, the United Kingdom, and Japan—toprovide excellent delivery time. Order by fax e-mail, or online and sendyour sequences to our synthesizers electronically, reducing deliverytime.

Choice of Quenchers

Applied Biosystems Custom TaqMan® Probes incorporate a 5′ reporter dyeand a 3′ quencher. Our most popular quencher is a non-fluorescentquencher (NFQ) combined with an MGB (minor groove binder) moiety. TheNFQ offers the advantage of lower background signal, which results inbetter precision in quantitation. The MGB moiety stabilizes thehybridized probe and effectively raises the melting temperature (T_(m)).This means that MGB probes can be shorter than traditional dual-labeledprobes, which make them better suited for allelic discriminationapplications. The shorter probe lengths mean that single base mismatches(e.g., SNPs) will have a greater destabilizing effect on an MGB probe,resulting in better discrimination. The shorter length also offersgreater design flexibility for all real-time PCR applications.

Applied Biosystems offers the traditional dual-labeled Custom TaqManProbes with a TAMRA™ dye fluorescent quencher as well. All TAMRA dyeTaqMan probes are HPLC purified.

A Selection of Reporter Dyes

Applied Biosystems Custom TaqMan Probes can be ordered with variety ofdifferent reporter dyes to facilitate your multiplexing applications.

Synthesis Scales

TaqMan Custom Probes and Primers are available in a choice of threestandard sizes. Each includes a pre-defined quantity of probe or primerto ensure that you get the same amount each time you order and aren'tsubject to variations in synthesis yield. For larger synthesis scales onthese products, please contact your local Applied Biosystems SalesRepresentative.

Primer Express® Design Software

Applied Biosystems Primer Express® software is available to simplify theprobe and primer design process. Primer Express is available forindividual users and in multi-user packs.

Other Fluorescent Dye-Labeled Oligos

Applied Biosystems also offers a host of other custom oligo products foruse in many applications, including microsatellite-based linkagemapping, mutation detection, and more.

CUSTOM TAQMAN PROBES AND PRIMERS Probe Type (3′ Quencher) Reporter Dye(5′) Label Quantity Probe Length TaqMan ® TAMRA ™ Dye 6-FAM ™ VIC ®, orTET ™  6,000 μmol Up to 35 bascs Probes 6-FAM, VIC, or TET 20,000 μmolUp to 35 bascs 6-FAM, VIC, or TET 50,000 μmol Up to 35 bascs TaqMan ®MGB Probes 6-FAM, VIC, TET, or NED ′″  6,000 μmol 13-25 bascs 6-FAM,VIC, TET, or NED 20,000 μmol 13-25 bascs 6-FAM, VIC, TET, or NED 50,000μmol 13-25 bascs Real-Time PCR Primers N/A 10,000 μmol N/A (sequencedetection N/A 80,000 μmol N/A primers) N/A 130,000 μmol  N/A

Please note that NED dye can give lower signal intensity than FAM, VICor TET dye or most Real-Time PCR Systems. The Applied Biosystems 7500Real-Time PCR System has been optimized to yield higher signal intensityfor NED dye.

TaqMan® MicroRNA Assays

TaqMan ® MicroRNA Assays Highly specific—quantitate only the Fast,simple, and scalable—two- biologically active mature miRNAs step qRT-PCRassay provides high-quality results in less than three hoursSensitive—conserves limited samples, Broad coverage—choose from requiresonly 1-10 nanograms of total human, mouse, rat, Arabidopsis, RNA orequivalent C. elegans, and Drosophila genes Wide dynamic range—up toseven logs—detect high and low expressors in a single experiment

By making novel adaptation in assay design, Applied Biosystems is ableto bring our gold standard specificity, sensitivity, and simplicity ofTaqMan® Assays and real-time PCR to miRNA detection and quantitation.

The basis of TaqMan® MicroRNA Assays is a target-specific stem-loopstructure, reverse-transcriptase primer. Its innovative design overcomesa fundamental problem in miRNA quantitation: the short length of maturemiRNAs (˜22 nt) prohibits conventional design of a random-primed RT stepfollowed by a specific real-time assay. The stem-loop accomplishes twogoals: 1) specificity for only the mature miRNA target, and 2) formationof a RT primer/mature miRNA-chimera, extending the 5′ end of the miRNA.The resulting longer RT amplicon presents a template amenable tostandard real-time PCR, using TaqMan Assays.

To ensure accurate results, every individual TaqMan MicroRNA Assaydesign has been functionally validated under laboratory conditions.

Distinguish Between Highly Homologous Mature miRNAs

TaqMan MicroRNA Assays are not only specific for mature miRNAs, they canalso successfully distinguish between highly homologous targets. As manymiRNA family members (i.e. the let-7 miRNA family) differ in sequence byas little as one base, real-time PCR using TaqMan Assays gives thespecificity needed for differentiation.

Requires Only Minimal Starting Materials

TaqMan MicroRNA Assays are extremely sensitive—researchers need only1-10 nanograms of purified total RNA or equivalent to reliably quantifytheir miRNAs of interest, not the several micrograms typically requiredfor hybridization-based methods.

Unparalleled Dynamic Range

TaqMan MicroRNA Assays deliver the wide linear, dynamic range TaqManAssays are known for—up to seven logs. This means that researchers canaccurately quantitate miRNA targets varying from a few copies tomillions of copies in the same experiment. This is an important factorgiven the wide range of miRNA concentrations within and across differentcells, tissue types, and disease states.

Fast Time-to-Results

By taking advantage of gold-standard TaqMan reagent-based technologywith universal thermal cycling conditions, TaqMan MicroRNA Assays arefamiliar, fast, and easy to set up. Just start with your total RNAsample, and get results in less than three hours using any AppliedBiosystems Real-Time PCR System.

Convenient and Scalable Solution

TaqMan MicroRNA Assays are pre-designed, functionally validated, andavailable off-the-shelf from Applied Biosystems, making them extremelyconvenient.

Broad Range of Species

TaqMan MicroRNA Assays are available for a range of species, includinghuman, mouse, rat, Drosophila, C. elegans, and Arabidopsis. Endogenouscontrols for human and mouse assays are also available. AppliedBiosystems will continue to increase the number of TaqMan® MicroRNAAssays for these species, with the goal of keeping aligned with theSanger miRBase Registry.

TaqMan® MicroRNA Reverse Transcription (RT) Kit

The TaqMan® MicroRNA RT Kit provides the necessary components foroptimal performance of TaqMan MicroRNA Assays. Components of this kitare used with the RT primer provided with the MicroRNA Assay to convertmiRNA to cDNA. This kit is available In 200 or 1,000-reaction sizes.

FIG. 35B illustrates the use of TaqMan® MicroRNA Assays and shows asimple, two-step mechanism that provides the advantages of real-time PCRto miRNA quantitation.

TaqMan ® PreAmp Master Mix Kit Amplifies cDNA targets Stretches 1 ng ofcDNA into 200 real-time equally without introducing PCH reactions forgene expression analysis bias using TaqMan ® Gene Expression AssaysMultiplex up to 100 gene Ideal for laser capture microdissections,expression targets with need le biopsies, and paraffin-embedded minimalhands-on time tissues

New TaqMan® PreAmp Master Mix (Early Access) from Applied Biosystemspreamplifies small amounts of cDNA without introducing amplificationbias to the sample. Gene expression analysis of scarce cDNA is no longerinaccurate and labor-intensive. The TaqMan PreAmp Master Mix Kituniformly enriches 1 to 250 ng of starting cDNA material for up to 100gene targets using a pool of TaqMan Gene Expression Assays as a sourceof primers. The PreAmp kit provides a simple, easy workflow andquantitative, reproducible results.

The standard real-time PCR reaction for gene expression analysis startswith the reverse transcription of total RNA to cDNA using randomprimers, followed by real-time PCR using a probe and gene-specificprimers. With the TaqMan PreAmp Master Mix, an intermediate multiplexstep between reverse transcription and real-time PCR is performed inwhich the cDNA is enriched for up to 100 gene targets using a pool ofTaqMan® Gene Expression Assays. The preamplification reaction is cycledfor 10 or 14 cycles to generate approximately 1,000 to 16,000-foldamplification of each gene-specific target. The resulting preamplifiedreaction is diluted and serves as the starting material for thesubsequent singleplex real-time PCR with each of the individual TaqMan®Gene Expression Assays represented in the assay pool.

Uniform, Unbiased Amplification

TaqMan® PreAmp Master Mix has been shown to provide virtually nodifference in the ΔΔC_(t) between preamplified cDNA from 1 ng to 250 ngof starting material and control cDNA. For these preamplified targets,TaqMan PreAmp Master Mix provides extremely high correlation between theCT values for cDNA and control cDNA for 1 ng and 25 ng of startingmaterial (data above).

Reliable and uniform preamplification enables researchers to analyzegene expression for limited quantities of cDNA samples from needlebiopsies, laser capture microdissections (LCMs), and formalin-fixedparaffin-embedded (FFPE) samples.

Complete Product Suite for Seamless Workflow

The TaqMan PreAmp Master Mix Kit comes with the new TaqMan PreAmp MasterMix and our TaqMan Universal PCR Master Mix. Both reagents work intandem to provide optimal preamplifcation of cDNA. In addition to theTaqMan PreAmp Master Mix Kit, other Applied Biosystems products requiredfor successful preamplification of cDNA include: TaqMan Gene ExpressionAssays; High Capacity cDNA Reverse Transcription Kit; GeneAmp® PCRSystem 9700; and Applied Biosystems 7300, 7500, 7500 Fast or 7900HT FastReal-Time PCR System.

FIG. 35C shows an example of a complete workflow for analyzing geneexpression using TaqMan® PreAmp Master Mix. In this example, thepreamplification step takes only about 15 additional minutes of hands-ontime and about 1.5 hours of cycling time.

Product Specification Comparison

Available Number of Reporter Universal Fill Volumes Reactions Dye LabelsFormulation TaqMan ® Gene Expression Assays Inventoried 250 μL, 20X 250(@20 μL) FAM ™ Yes Made to Order 360 μL, 20X 360 (@20 μL) FAM Yes CustomTaqMan ® Gene Expression Assays Small-scale 360 μL, 20X 360 (@20 μL) FAMYes Medium-scale 750 μL, 20X 750 (@20 μL) FAM Yes Large-scale 967 μL,60X 2,900 (@20 μL)   FAM Yes TaqMan ® Endogenous Controls Primer limitedVIC Yes Not primer limited FAM Yes Custom TaqMan ® Probes and PrimersFAM No VIC No TET No NED No TaqMan ® PreAmp 1 mL  40 (@50 μL) Master MixTaqMan ® MicroRNA 150 (@20 μL) FAM Yes Assays Custom TaqMan ® Low 384(@1 μL)  Density Arrays^(†) TaqMan ® Low Density 384 (@1 μL)  Array GeneSignature Panels^(‡)

TaqMan® Low Density Array Gene Signature Panels

Number of Targets/ Gene Signature Panel Name Controls Format Pack SizeHuman Immune Panel 90/6 Formal 96a 4 cards/pack Mouse Immune Panel 90/6Formal 96a 4 cards/pack Human Protein Kinase Panel 94/2 Formal 96a 4cards/pack Human GPCR Panel 367/14 Formal 384 4 cards/pack Mouse GPCRPanel 365/16 Formal 384 4 cards/pack Human ABC Transporter Panel  50/14Format 64 4 cards/pack Human Apoptosis Panel 93/3 Formal 96a 4cards/pack Human Endogenous Control 16 Formal 16 2 cards/pack PanelMouse Endogenous Control 16 Formal 16 2 cards/pack Panel Rat EndogenousControl Panel 16 Formal 16 2 cards/pack

Some Novel Features of Certain Embodiments

The array printing, hybridization, quantitative development and assayingsystems and methods of embodiments of the invention provide severaladvantages some of which relate to high throughput abilities andconservation of valuable liquids or reagents. The following representsome, but not limited to, novel and/or unique features, aspects andadvantages in accordance with certain embodiments:

(1) Some embodiments provide bulk dispenser configurations andsoftware/motion transformations that allow the use of dispensers inarrays with large spacing to configure dense packed arrays on thesubstrate at high speeds with controlled drop volumes. In some of theseembodiments, one dispense line is always connected to a specific reagentor liquid. In some of these cases, no aspiration steps are performed.

(2) In some embodiments, the arrayed dispensers can be used tomanufacture not only fixed arrays but also desirably any possible arraythat consists of or comprises a sub-segment of these dispensers.

(3) Certain embodiments have the capability of dispensing drops havingvolumes ranging from about 1 microliter (μL) down to about 100picoliters (pL) or less with spot sizes greater than about 1 mm downinto the range of 50 microns (μm) or less, including all values andsub-ranges therebetween. In some embodiments, the drop size or volume isin the range from about 20 picoliters (pL) to about 1 microliter (μL),including all values and sub-ranges therebetween.

(4) Some embodiments advantageously provide array designs and webdesigns that allow for high speed processing and tracking.

(5) In some embodiments, any optical detection technology may beefficaciously utilized. These include, without limitation,chemoluminescence, fluorescence, and absorption, among others, as neededor desired.

(6) Certain embodiments desirably utilize a drop on drop methodology forhybridization and/or other assaying processes. In some embodiments, aninert substrate is employed. In some other embodiments, an activesubstrate is used. Certain related embodiments advantageously includethe use of the drop kinetic energy to assist in good mixing toefficaciously enhance the reaction kinetics.

(7) Some embodiments advantageously use tandem motion systems on or inconjunction with hybridization and/or other assaying systems todesirably achieve a high throughput process by putting or dispensingsample drops on the array spots using otherwise inherently slowprocesses such as the aspirate/dispense process.

(8) Certain embodiments desirably utilize the web format for arrayswhich provides for simple blocking, drying and washing of active arrayformats to achieve the ability for high throughput processing.

(9) In some embodiments, belts of a substrate are utilized which candesirably provide the capability to carry thousands (and in some caseseven more) of arrays. This advantageously allows for a continuousincubation and readout system.

The methods which are described and illustrated herein are not limitedto the sequence of acts described, nor are they necessarily limited tothe practice of all of the acts set forth. Other sequences of acts, orless than all of the acts, or simultaneous occurrence of the acts, maybe utilized in practicing embodiments of the invention.

It is to be understood that any range of values disclosed, taught orsuggested herein comprises all values and sub-ranges therebetween. Forexample, a range from 5 to 10 will comprise all numerical values between5 and 10 and all sub-ranges between 5 and 10.

From the foregoing description, it will be appreciated that a novelapproach for diagnostic arraying and/or assaying has been disclosed.While the components, techniques and aspects of the invention have beendescribed with a certain degree of particularity, it is manifest thatmany changes may be made in the specific designs, constructions andmethodology herein above described without departing from the spirit andscope of this disclosure.

While a number of preferred embodiments of the invention and variationsthereof have been described in detail, other modifications and methodsof using and diagnostic applications for the same will be apparent tothose of skill in the art. Accordingly, it should be understood thatvarious applications, modifications, and substitutions may be made ofequivalents without departing from the spirit of the invention or thescope of the claims.

Various modifications and applications of the invention may occur tothose who are skilled in the art, without departing from the true spiritor scope of the invention. It should be understood that the invention isnot limited to the embodiments set forth herein for purposes ofexemplification, but is to be defined only by a fair reading of theclaims, including the full range of equivalency to which each elementthereof is entitled.

What is claimed is:
 1. A high speed assaying system, comprising: anarray substrate comprising at least about forty target spots formedthereon in an array arrangement with center to center spacings of theorder of about 1 mm between adjacent spots; a dispense module comprisinga dispense head, the dispense head comprising a plurality of non-contactdispensers arranged in a predetermined configuration with apredetermined spacing for dispensing reagent drops onto the arraysubstrate with target spots formed thereon or therein such that thedrops are precisely delivered at the position of the selected targetspots to execute an assay or reaction; a controller to monitor andcontrol the dispensers and relative motion between the dispensers andthe array substrate; wherein when the system is in use the dropscomprise a part of the system; and wherein the system is configured toproduce at least about ten million assayed substrates per year.
 2. Thehigh speed assaying system of claim 1, wherein the dispensers comprisesolenoid actuated dispensers.
 3. The high speed assaying system of claim1, wherein the array substrate comprises an inert or passive substrate.4. The high speed assaying system of claim 1, wherein the arraysubstrate comprises an interactive or active substrate.
 5. The highspeed assaying system of claim 1, wherein the array substrate comprisesa membrane.
 6. The high speed assaying system of claim 1, wherein thearray substrate comprises a film and a carrier arranged in a web format.7. The high speed assaying system of claim 1, wherein the arraysubstrate comprises a sheet format.
 8. The high speed assaying system ofclaim 1, wherein the system further comprises at least one tandem motionsystem to achieve high throughput and substantially continuousoperation.
 9. The high speed assaying system of claim 1, wherein thedrops are dispensed at a predetermined velocity and/or momentum toprovide enhanced mixing and/or reaction kinetics with the selected arrayspot.
 10. The high speed assaying system of claim 1, wherein the arraysubstrate comprises a membrane, and wherein the system further comprisesa membrane handling system.
 11. The high speed assaying system of claim1, wherein the system further comprises a sample storage machine tostore sample plates, and wherein each of the sample plates comprises atleast one array substrate.
 12. The high speed assaying system of claim11, wherein the sample plates comprise identifiers.
 13. The high speedassaying system of claim 12, wherein the identifiers comprise barcodeidentifiers.
 14. The high speed assaying system of claim 12, wherein theidentifiers comprise punch card identifiers.
 15. The high speed assayingsystem of claim 12, wherein the identifiers comprise Radio FrequencyIdentification Device (RFID) identifiers.
 16. The high speed assayingsystem of claim 1, wherein the assaying comprises hybridization, andwherein the reagent drops and the target spots are selected such thatwhen the drops and spots interact the hybridization is executed.
 17. Thehigh speed assaying system of claim 1, wherein the assaying comprisesPCR assaying and the substrate comprises a PCR plate.
 18. The high speedassaying system of claim 17, wherein the spots comprise at least oneoligonucleotide.
 19. The high speed assaying system of claim 18, whereinthe oligonucleotide comprises a TaqMan® probe.
 20. The high speedassaying system of claim 17, wherein the reagent drops are dispensedthrough a layer of oil covering the spots.
 21. The high speed assayingsystem of claim 1, wherein the reagent drops comprise a sample of one ormore preselected reagents.
 22. The high speed assaying system of claim20, wherein the system further comprises a thermal cycling module toprocess the PCR plate.
 23. The high speed assaying system of claim 22,wherein the system further comprises a read module downstream of thethermal cycling module.
 24. The high speed assaying system of claim 1,wherein the dispensers comprise piezo dispensers.
 25. The high speedassaying system of claim 1, wherein the array substrate comprises aglass slide.
 26. The high speed assaying system of claim 1, wherein thereagent drops comprise a master mix.
 27. The high speed assaying systemof claim 1 in combination with a high speed array manufacturing systemto form a combination comprising a high speed array manufacturing systemand the high speed assaying system.
 28. The combination of claim 27,wherein the high speed array manufacturing system is configured toproduce at least about one million array substrates per year.
 29. Thecombination of claim 27, wherein the controller is configured to usedispensing data from a text file in cooperation with a software programwhich is interfaced to the controller to precisely control andcoordinate dispensing of the reagent drops, and wherein the text file isa user-defined text file created from a spreadsheet of values ortemplate with lists of numbers of user-defined dispense volumes of oneor more reagents and corresponding coordinates of the dispenselocations.
 30. The combination of claim 27, wherein the combinationfurther comprises a tandem fluid source system which comprises tworeagent sources correspondingly coupled to each dispenser, and whereinthe tandem fluid source system is configured to sequentially fill anddispense reagent from each dispenser so that high throughput andsubstantially continuous operation of each of the dispensers isachieved.